Process Overview
Surface Preparation
Surface Preparation
Surface Preparation
Successful powder coating begins long before the powder is applied, it starts with meticulous surface preparation. Every part must be thoroughly cleaned to eliminate dirt, oils, and contaminants that could compromise adhesion. A clean substrate isn’t just preferred, it’s essential for achieving a durable, high-quality finish.
Preparation is a multi-step process, and it’s not only about what gets removed, it’s also about what might be left behind. Residual contaminants, even in trace amounts, can undermine coating performance. That’s why the effectiveness of pretreatment cleaners is critical. While most modern formulations handle oils and light greases well, the rise of advanced surface technologies like zirconium demands even greater precision and reliability from these products.
Powder Application
Surface Preparation
Surface Preparation
The dry powder is applied to the surface, using a specialized spray gun that electrostatically charges the powder particles. Here, the metal part is electrically grounded, while the spray nozzle imparts a negative electrostatic charge to the powder particles. The particles are shot towards the metal, either mechanically or through compressed air. Once airborne, they’re accelerated by the electrostatic attraction between the negatively charged particles and grounded metallic surface. A variety of nozzles help cater the powder coating process to unique part shapes.
Curing
Quality Control
Quality Control
Once the powder is applied, the coated part undergoes a controlled curing process. Heated to temperatures between 350°F and 400°F, the powder melts, flows, and chemically cross-links to form a smooth, uniform finish. This fusion creates a durable coating that resists chipping, corrosion, and wear—ensuring long-term performance and aesthetic appeal.
Quality Control
Quality Control
Quality Control
Following the curing process, the coated surface undergoes a thorough inspection to verify that the finish is smooth, uniform, and free from defects or imperfections. Any irregularities identified during this stage are addressed promptly through repairs or touch-ups to ensure the coating meets the required standards.