Winona Powder Coating offers top quality electrocoat (E-Coat) services serving customers throughout the country. With our new TTX Indexing E-Coat line with 13-Stage Pretreat and Zinc Phosphate, we provide the convenience and flexibility to meet the demanding requirements of today’s manufacturing environment. Learn more about our services and E-Coating to decide if it’s the right choice for you.
E-Coating, or electrocoating, is a finishing process by which electrically charged particles are deposited out of a water suspension using an electrical current to coat a conductive part. During the E-Coat process, paint is applied to a part at a particular thickness regulated by the amount of voltage applied. Electrocoat solids initially deposit in the areas closest to the counter electrode. As these areas become insulated to current, solids are forced into more recessed bare metal areas to provide complete coverage.
The electrodeposition continues until the desired level of coating thickness is accomplished, controlled by increasing or decreasing the voltage level. The coated part is then cured in an oven to promote cross-linking.
In cathodic systems, the product or part is negatively charged, attracting the positively charged paint particles. The part's negatively charged polarity reduces the amount of iron entering the cured paint, enhancing the corrosion resistance and durability and reducing contamination in the baths that would then have to be filtered out. Cathodic E-Coatings boast high-performance and excellent corrosion resistance. If you are going to E-Coat, this is the best method.
Cathodic Epoxy E-Coatings are the standard for corrosion resistance. Generally used in the automotive and automotive parts industries, they provide superior salt spray, humidity, and cyclic corrosion resistance. However, the cathodic epoxy technologies typically require a topcoat to be protected from sunlight. Aromatic epoxy-type coatings are particularly prone to chalking and degradation by the UV components of sunlight.
Cathodic Acrylic E-Coatings are available in a wide range of glosses and colors to maximize exterior durability, gloss retention, color retention, and corrosion protection. These products are used in the agricultural, lawn and garden, appliance, and air-conditioning industries. Cathodic acrylic E-Coatings are typically used in applications where both UV durability and corrosion protection are desired.
Superior cathodic epoxy electro-coating can be achieved through a distinct 4 step process. Firstly, the metal is cleaned and treated with phosphate. The coatings are then applied to the pretreated metal by a controlled voltage in an electro-coat bath with a mixture of deionized water and paint solids. This step is complete once the desired coating thickness is reached, and the part is insulated. These paint solids contain a resin that provides the corrosion resistance and durability of the coating. Once the metal has been coated, it is then rinsed, which allows for the reclaiming of excess paint. Finally, the coated part is now placed into a bake oven that will cure and cross-link the paint film to maximize its performance properties.
E-Coat: AquaEC 6100 Series
The AquaEC 6100 series from Axalta Coating Systems is a family of cathodic E-coat primers based on enhanced epoxy resins and innovative tin-free catalyst. The technology used in this family of products is designed for many end-use markets ranging from automotive to industrial applications.
Specifically designed to deliver enhanced corrosion resistance, performance, and productivity, the AquaEC 6100 series provides excellent coverage and application properties.
Superior performance over mixed substrates and pre-treatment systems makes this E-Coat series ideal for today’s advanced layering systems. AquaEC 6100 series is formulated to meet market demands that reflect different substrates, parts designs, and pre-treatment options. With its excellent mechanical properties, superior corrosion resistance, and enhanced edged protection, this series delivers performance exceeding the competition.
The low-temperature curing properties of AquaEC 6100 technology helps to reduce energy costs while its high throw power provides optimized film build distribution across all surfaces.
AquaEC 6100 is an industry leader in bake loss, resulting in less film shrinkage and increased coverage per gallon of paint. The innovative tin-free technology used to formulate AquaEC 6100 products helps address environmental concerns and make it Axalta’s most advanced E-Coat.
Cathodic Electro-coating (E-Coat) uses electrical currents to attach an organic coating from a paint bath onto a part or pre-assembled product. With the ability to impale recess and coat complex parts, is used worldwide throughout many industries. Whether automotive or agriculture, cathodic electro-coating has driven improvement in corrosion resistance over those presented by anodic electro-coating.
Widely used, cathodic epoxy electro-coatings are the standard for corrosion resistance. Perfect for automotive or agriculture industries, they provide superior humidity, salt spray, and cyclic corrosion resistance. These electro-coatings have become quite popular as a primer due to its excellent adhesion and corrosion protection. To provide resistance to ultraviolet (UV) rays from sunlight, cathodic epoxy electro-coatings are compatible with many powder and liquid topcoats.
Corrosion and Wear Resistance
Our customers choose electrocoating to provide their products with a durable, long-lasting finish. E-Coat is a technology used to achieve high-quality, low-cost finishes at a level of efficiency and environmental compliance; no other finishing method approaches. The performance advantages and reduced finishing costs have made it a thriving technology that will continue long into the future as new uses and technologies develop
Virtually all unused paint is recovered in the electrocoating process. Our line has a three post rinse to remove any residual buildup. The post rinses are then filtered, and any paint collected in the rinse stages is reintroduced into the application bath. Our E-Coat system is automated, the amount of paint applied to a product can be precisely controlled, yielding minimal waste, unlike powder or paint overspray.
E-Coating is environmentally friendly because the process produces little to no VOCs (Volatile Organic Compounds), HAPS (Hazardous Air pollutants) and is RoHS, OSHA, and EPA compliant. Environmental advantages include eliminating the need for costly air abatement equipment present with many solvent-based liquid sprays or dip processes. Electrocoating products are free of heavy metals and have low BOD/COD if introduced to waste streams. Products are water-based, thus reducing fire hazards and worker exposure to hazardous materials.
Electrocoat is usually the lowest-cost finishing application. The keyword is “application.” Anytime cost to paint parts is evaluated, customers need to look beyond the material cost per square foot or the cost per gallon. Some of the significant factors that enter into the equation for the application selection include:
- Part complexity: Parts come in all shapes and sizes. E-Coat excels over other technologies in this category because all surfaces receive a consistent film thickness due to the electrical insulating effect as it deposits onto the part.
- Production volume: As manufacturers increase production quantities above 2 million sq.ft. annually per shift, electrocoating becomes a more preferred application method. The dense rack loading achieved with E-Coating allows manufacturers to produce a greater volume of parts.
- Repair and maintenance: There is usually more mechanical equipment associated with E-Coating; however, the labor requirements to maintain a liquid or powder system are generally greater.
- Paint material: Electrocoat is usually the most cost-effective when comparing applied paint materials. This is due to the high transfer efficiency and the self-limiting ability of the electrocoating process.
- Capital: After other cost variables, such as film thickness and labor requirements, are taken into consideration, the E-Coat process produces the cheapest coating on an applied-cost-per-square-foot basis.
The lower total usually drives the choice of electrocoating over other coating technologies like liquid spray and powder coatings. The low total applied cost is achieved in part through a more consistent deposition of paint film on parts (incredibly complex geometries), high transfer efficiencies, and the lower costs associated with labor.
Contact Winona Powder Coating
E-Coating technology has continued to evolve. More industries are choosing electrocoating for its cost-effectiveness, high-efficiency, and versatile technology options. In addition to the auto industry, E-Coating is now prominently used in manufacturing heavy equipment, electrical components such as switchgear, fasteners, and just about any metal product where superior corrosion protection is required.
Winona Powder Coating LLC offers an innovative E-Coating process in the Midwest that is exceptionally effective at preventing corrosion while also providing increased substrate durability. Along with our standard E-Coat process we offer packaging and assembly services. Contact us today to learn more about how E-Coating can benefit you.