What is E-Coating? E-Coating is a method of metal finishing which uses electrical current to deposit paint from a water-based solution. The fundamental physical principal of E-Coat is that materials with applied opposite electrical charges attract each other. An E-Coat system applies a DC charge to a metal part immersed in a bath of oppositely charged paint particles. The paint particles are drawn to the metal and the paint deposits on the part forming an even, continuous film over the surface and in every crevice until the coating reaches the desired thickness. At that thickness the film insulates the part so attraction stops and the coating is complete. The name E-Coat is an abbreviation of "electrophoretic coating", but it is also commonly called "electrocoat". This is one of the most rapidly growing sections of the finishing industry with advantages in both cost and performance over most other systems.

How is it applied? Our plant is a computer controlled hoist operation where the work is mounted on specially constructed racks and processed through cleaning and pretreatment operations. The coating process is applied with electrical power that can reach 400 volts, requiring safety measures far in excess of any electroplating operation. Once coated, the work is rinsed in a unique manner where all excess coating is returned to the coating tank, creating a closed loop process. The work then proceeds through an oven to cure the coating.

What are the advantages over conventional finishing systems? E-Coat has the property of coating all surfaces that come in contact with the solution. It is ideally suited for coating assemblies where recesses and raised surfaces all receive the same coating thickness, i.e. a tube section will be coated down the centre as well as on the outside. Most conventional coatings such as powdercoating or electroplating do not coat recesses which is the first failure point for corrosion. The uniformity of the coating overcomes many problems that users find with conventional coatings, such as the build-up on threads which then requires post-coating operations.

Are there cost savings? E-Coat is designed for mass production with the work being loaded onto racks for processing. Although the capital expenditure for the initial installation may be considerable, the production rate is greater than most other finishing procedures and substantial savings can be made in many applications.

What pretreatment is used for the E-Coat process? We use zinc phosphate which is specified by the automotive industry for use with this finish; zinc phosphate gives excellent corrosion protection with E-Coat finishes withstanding up to 1000 hours salt spray testing.

Who is using E-Coat? The major demand in Australia is from the automotive industry where the performance, cost and environmental benefits are required. Overseas the use of E-Coat is rapidly expanding with its use showing strong growth in many industries where it's ability to deposit coatings uniformly over all surfaces shows cost and performance advantages well above other finishes.

Is the product environmentally friendly? The finishing industry generates many chemical waste products that may be considered environmentally unfriendly. Plating processes generate heavy metal waste, powder and paint processes also can generate undesirable waste products. E-Coat is designed to operate as a closed loop process, giving rise to very low waste discharges back into the environment.

What colours are available? Our plant is designed to produce semi gloss black coatings.

Is E-Coat suitable for outdoor exposure? The formulation of our E-Coat process is designed for corrosion resistance and good performance for interior and underbody automotive applications. Our E-Coat formula will show signs of chalking with full outdoor exposure, although this will not effect its corrosion resistance.

Can E-Coat be used as an undercoat to powder or paint? The formulation of our E-Coat tank is suitable for over coating with paint or powder. The combination of the E-Coat base and powder give a finish suitable for full exterior exposure.

What is the coating thickness? The coating thickness ranges from 15 microns to 30 microns subject to the voltage applied and will maintain this thickness evenly over all surfaces.

For more information on E-Coat or to find out how Finished Products can help you achieve outstanding results for your surface finishing requirements, please feel free to contact us by telephone on +612 9602 9833 or send us an email by clicking on the "Contact Us" link below.