Powder coating is a finishing process of a material to protect them from wear and tear as it creates a protective layer on the object. Mostly, it is used for aluminium as it improves durability, aesthetic appeal, offers resistance and prevents corrosion, etc. There are two types of powder coating – electrostatic spray deposition (ESD) and fluidized bed application.
Aluminium powder coating is also known as the electrostatic spray deposition process, as the coating is done by spraying electrostatically charged dry powder over the material surface. It offers a wide range of colors based on people’s requirements and is used for various products. However, numerous manufacturers are adapting this technique as it comes with multiple benefits and is environmentally friendly as well. In this blog, we will explore the process and benefits of aluminium powder coating.
The Process of Powder Coating
Aluminium powder manufacturers in India follow a multiple-step process to coat the material. However, it is categorized into three steps.
- Preparation Stage
The preparation of the material surface is necessary before doing the powder coating to ensure the durability and quality. If the surface of the substrate is not cleaned, there is a chance that residue of dirt will be left behind. These remaining residues can affect the adhesion of powder to the material surface. In the process of surface preparation, dirt, grease, and other impurities are removed from the surface. The cleaning process has several steps, such as cleaning, rinsing, etching, blasting, drying, etc.
The surface cleaning process followed two processes – chemical cleaning and conversion coating.
Chemical cleaning:
In the chemical cleaning process, Aluminium powder manufacturers in India use mild acids, detergents, and alkalies(caustic soda). It is rinsing in hot water, steam, etc., to clean the material surface. However, the nature of acid cleaners depends on the material type that needs to be coated. For instance, aluminum requires mild alkaline cleaners as it is sensitive to acid attacks. After the completion of the cleaning process, all the oil, grease, and impurities left that smoothen the surface.
Conversion Coating:
In this process, conversion coating is done to strengthen the adhesion of powder coating, so it is applied on the material’s surface. The chemical solution that is used for the conversion coating is selected based on the material nature. For instance, aluminum uses a mild steel solution due to its sensitive nature toward acids. This rinsing process removes the chemical salts and other residues from the surface that can lead to corrosion. After the conversion coating, the material is moved into the oven to remove all the moisture, so the powder coating will be strong.
- Application Stage
Once the material is moved from the oven, powder coating is applied. This process can be done by electrostatic spray deposition and fluidized bed powder coating.
Electrostatic Spray Deposition:
In the ESD method, the powder coating is done by spreading the ground powder to the material with the help of a gun. The gun consists of a spray booth, a powder feeder, an electrostatic spray gun, and a power unit.
Fluidized Bed Powder Coating:
In this process, the powder is applied to the coating material electrostatically that adheres to the surface.
- Curing Stage
The third and final step is curing. This step sends coated material to the oven and is heated at 2000C. Due to the high temperature, powder fuses and melts, allowing them to flow together and form a film to create a smooth surface.
Benefits of Powder Coating
Many aluminium powder manufacturers in India use powder coating as it comes with several advantages.
- Durability
Powder coating prevents wear and tear, and an aluminium powder coating is the highly resistant to wear and tear. The coating also protects from fading, chipping, scratching, and wearing. Metal that comes in contact with sunlight must be coated to improve its durability.
Generally, paint fades after contact with sunlight, so powder coating comes into the picture as it slows down the fading process due to UV resistance. Apart from it, the coating also prevents any damage. For instance, rust is dangerous to the metal when metal is exposed to moisture and outdoor air; coating saves metal from coming into contact.
- Longevity
The coating is durable, making the material exist for a long time. Powder coating appears on the material for a long time, offering the material a long life.
- Save Time and Money
Powder-coated material has a longer life, saving you money in the long run, and its process is also quicker than other painting methods, saving you time. It doesn’t take time to dry compared to the normal painting process.
- Eco-Friendly
On top of all the advantages, powder coating is eco-friendly. In this process, the powder is sprayed on a material that contains no harsh chemicals. As powder coating is done through the electric charge on the surface, and there is not any solvent used.
The Bottom Line
Powder coating is the final step of a material finish, offering a better finish and color. It has various advantages, such as creating a protective layer, making the material durable and long-lasting. It also saves you time & money and is eco-friendly. JM Aluminium is an aluminium powder manufacturers in India that offers you superior powder quality with a variety of color variants. We facilitate timely delivery anywhere at your doorstep, and our skilled engineers are ready to assist you 24*7 at every step of the process.
