Powder coating aluminum is a sort of covering which is applied on aluminum substrate as a free-streaming dry powder. Traditional liquid paint is conveyed through an evaporating solvent, while powder coating is normally applied electrostatically and afterward cured under heat or with UV light. The powder can be a thermoplastic or a thermoset polymer in nature.
Powder coating is generally used to make a thick, intense finishing that is much strong than regular paint. Powder coating is predominantly used for coating of metal articles, especially those subject to harsh use. Advance examination brings about powder coating innovation like UV-treatable powder coatings which consider different materials like plastics, composites, carbon fiber, and MDF (medium-thickness fiberboard) to be powder coated, as little intensity or stove abide time is expected to process them.
Aluminum Powder Coating (Basics)
Aluminum is light weight and possess strong properties, that’s why it is utilized in different sectors including automotive and aviation. However, if surface of aluminum is not treated as required that can be suspected to corrosion and rust. Powder coating aluminum gives an additional layer of protection against these components. This protective layer can last for many years with minimal cost of maintenance. Powder coated aluminum is a normal aluminum-based product which is subjected to coating made of different resins and polymers.
This provides improved designs, corrosion resistance and durability to aluminum material and extrusions. Powder coating is widely applied on aluminum extruded products. The application method of the coating is same as the spray paints. The goal is to provide a better finish and color to the final product for adding a decorative element in it. Moreover, additional benefits of increased corrosion resistance and wear resistance to product helps in maintaining the properties and features for long duration.
Aluminum Powder Coating Process-How to powder coat aluminum
Powder coating on aluminum surface is deposited by using electrostatic spray deposit method. A powder spray device is utilized to precipitate the coating particles over the aluminum. Coating material is made out of different polymers, for example, epoxy, acrylic, polyurethanes which are added with color, stream modifier, curing agent, and additive. These are added to guarantee that coating material is applied over the item in an even way.
Below is process for how to powder coat aluminum which mainly comprises of following steps:
1.Surface Preparation
Aluminum items are exposed to pre-treatment baths to clean the pollutants, and oil. Legitimate surface planning is exceptionally basic for guaranteeing that powder coating sticks accurately and the finishing is smooth and strong. This step is fundamental for legitimate bond of covering over the item.
Cleaning: The aluminum surface is entirely cleaned to eliminate any soil, oil, or grease. This is carried out by using cleaners or solvents.
Etching: In order to provide more improved surface for better coating aluminum is often etched with an acid solution. That will eliminate oxides and make a somewhat rough surface that will assist the powder to stick better.
Rinsing: Subsequent to cleaning and etching process, the aluminum is flushed with deionized water to eliminate any leftover synthetics if present.
Drying: In this step drying process is done because aluminum should be totally dried to keep any dampness from obstructing the powder coating process.
2.Application of Powder
When the surface is ready, the powder coating is applied by utilizing an electrostatic spray gun.
Electrostatic Spraying: In this step the powder which is comprised of finely ground particles of pigment and resin is charged electrostatically and showered onto the grounded aluminum parts. The electrostatic charge makes the powder particles grip to the outer layer of the aluminum part.
Manual or Automatic Application: This is utilized where part is of complex design. The powder can be applied manually by a technician or automatically using robotic arms depending on the complexity and size of the part.
3.Curing Process
This process is done in curing oven by following these two steps.
a) Heating: At a temperature between 77°C to 204°C parts are heated for 10-20 minutes. This intensity of heat makes the powder to melt and flow, providing a persistent uniform film.
b) Polymerization: During the curing system, the powder goes through a chemical reaction called cross-linking, where the powder particles synthetically cling to shape a hard, sturdy finishing.
4.Quality Control
Inspection is done to ensure quality as per following steps.
a) Visual Inspection: The coated parts are visually checked for any surface defects such as nonuniform coating and deformations.
b) Thickness Measurement. In this step a micrometer or magnetic gauge is used to measure the thickness of the coating. This is done to ensure that coating meets specifications according to requirement
c) Adhesion Testing: The coating adhesion with metal substrate is tested by performing cross-hatch attachment test in this step.
Benefits of powder coated aluminum
Powder coated aluminum surface has ended up being a powerful method for applying defensive and beautifying covering. This is on the grounds that it has many benefits, as follows:
1.Durability
a) Enhanced Surface Protection: Powder coating gives a thick, defensive layer that safeguards aluminum parts from scratches, chipping, and different types of wear.
b) Corrosion Resistance: The applied coating successfully seals the aluminum surface, subsequently shielding it from corrosion and oxidation, which is especially valuable in extreme conditions.
2.Aesthetics
Wide Range of Colors and Finishes: Powder coating aluminum gives many options for wide selection of colors and finishes. This provides designers with extensive creative flexibility.
Consistency: There are no drips and sags which are common with liquid paints, as powder coating process ensures a uniform finish.
3.Environmental Advantages
a) Low Volatile Organic Compounds: Powder coating emits minimal volatile organic matter that’s why it is environment friendly.
b) Recyclability: This is important advantage in which over sprayed coating is collected and reused. Consequently, this outcomes in decreasing waste and advancing supportability.
4.Cost-Effectiveness
a) Efficiency: The powder coating process is efficient and quick that’s why its very cost effective. Thus, reducing the labor costs and production time.
b) Longevity: Powder coating increase the lifespan of the items which makes the aluminum products more durable. This ultimately results in minimal replacement and maintenance.
5.Performance in Harsh Conditions
a) Weather Resistance: Powder coated aluminum items can endure outrageous weather patterns, including UV radiation, rain, and humidity. This makes it ideal to produce outdoor items.
b) Chemical Resistance: Powder coated aluminum items gives great obstruction against numerous synthetic substances, upgrading its appropriateness for modern applications.
6.Mechanical Properties
a) Flexibility: The coating applied on aluminum items can flex with the metal without breaking, chipping or stripping, which is extremely critical for applications where the material might twist or move.
b) Impact Resistance: Aluminum parts when powder coated, improve the impact resistance of aluminum. This outcomes in decreasing the risk of destruction when stresses are applied.
7. Maintenance
a) Easy to Clean: In daily routine this benefit comes in handy as smooth surface of powder coated aluminum makes it easy to clean and maintain by just using soap and water.
b) Stain Resistance: Powder coated aluminum products are resistant to staining, which helps in maintaining its appearance over the period time.
8.Application Versatility
a) Suitability for Complex Shapes: Powder coating can be applied to aluminum items possessing complex and complicated shapes. This makes it exceptionally convenient and flexible for many design requirements.
b) Vast Range of Usage: Powder coated aluminum has wide range for its applications. Mainly it covers different enterprises, including automotive, development, furniture, and home appliances.
Limitations of powder coating aluminum
Aluminum powder coating process also have some disadvantages. That includes Followings:
- Processing time is relatively longer.
- Control over the process variables is difficult
- A range of machinery is required for whole process
Applications of powder coated aluminum parts
Powder coating aluminum items has a great many applications due to its durability, stylish allure, and protection from corrosion. Some major applications are followings:
1.Architectural and Building Materials
a) Window Frames and Doors: Powder coated aluminum is for the most part utilized for window frames and doors in view of its protection from weather and its capacity to keep color and finish over the long-time span.
b) Facade Panels and Cladding: Powder coated aluminum is many times utilized in outside cladding and exteriors for both business and private structures.
c) Railings and Fencing: The solidness of Powder coated aluminum makes it ideal material for railings, fencing, and overhang nooks.
2.Automotive sector
Automotive Parts: Powder coated aluminum parts finds their vast applications in automotive sector. In automotive sector components such as wheels, trim, and engine parts are often powder-coated to protect them from the environmental factors and enhance their appearance as well.
3.Furniture
a) Outdoor Furniture: Powder coated aluminum when exposed to water, sun and rain gives corrosion resistance and maintain its properties. Subsequently this property makes it ideal to be used for manufacturing outdoor furniture.
b) Indoor Furniture: Indoor furniture is also manufactured from powder coated aluminum which provide amazing looks and aesthetics.
4.Consumer Products
a) Appliances: various Pieces of machines like fridges, clothes washers, and stoves can be powder-coated to give a strong and alluring look.
b) Electronics: Electronic sector frequently use powder coated aluminum to achieve protection and aesthetics.
5.Industrial Applications
a) Machinery and Equipment: In a modern industrial arrangement machinery and equipment is prone to wear and corrosion. Subsequently Powder coating is applied in different enterprises to safeguard machinery and equipment against wear and tear.
b) Tools: Handles of various devices and different parts can be powder-coated to further develop grip and sturdiness.
6.Lighting
Lighting Fixtures: Powder coated aluminum has great capacity to get through high temperatures and extreme ecological circumstances, consequently it is utilized in the development of both indoor and open-air lighting appliances.
7.Signage
Commercial Sign: Commercial and information signs are produced from powder coated aluminum as it is available in vast range of colors.
These applications benefit from the durable finishing, good protection against rust and corrosion, and the stylish flexibility that powder coating offers.
Conclusion
Powder coating on aluminum items adds corrosion and wear resistance and toughness as well as engaging look. Furthermore, it is also used to add decorative elements in the aluminum product because of its good surface finish. Powder coating when applied to aluminum which is light weight with high strength it brings out high corrosion resistance permitting it to be utilized in numerous applications. The toughness of aluminum powder coating is significantly longer than the ordinary coatings. Aluminum powder coating is exceptionally savvy and harmless to the ecosystem for the majority outdoor applications.