E-coating Basics

It is often said that E-coating (also known as Electrophoretic Coating, EDP, Electropainting, KTL, Kathodische Tauch Lackierung, CDP or Cathode Dip Painting) is one of industry’s most efficient coating methods. The process allows parts to be uniformly coated in seconds with tough, chemically resistant materials. These coatings are deposited from a water-based solution using a high voltage DC charge. The process coats all wet surfaces with a highly corrosion resistance finish that is unlike any other process. The automotive industry has long been a user of this process for the undercoating of car bodies and it is largely responsible for all but eliminating rust in modern vehicles.

The nature of the process and the way e-coating plants are designed gives nearly 100% coating utilisation, making it an environmentally friendly finish.

Like many of our finishing processes, the components need to be racked on special electrically conductive racks before being processed through a number of cleaning and chemical pre-treatment stages. The components then enter the e-coat bath for the brief coating process. After this, the parts are rinsed and baked at around 190°C.

The process is very much tailored to bulk production runs where large quantities of parts can be racked in the most efficient manner possible on specially designed racks. As the colour is incorporated in the coating bath and different colours mean different baths, changing colours on this process is limited to large volumes of ongoing work only.

Using e-coat as an undercoat and applying powder as a top coat gives a unique combination of finishes that has the protection and recess covering of the e-coat with the colour and flexibility of powdercoating.

The large majority of e-coating done by Impreglon Australia is a corrosion resistant black interior coating. Clear UV resistant coatings can also be applied for certain exterior applications.

Due to the uniformity of the coatings, tapped holes, threaded exposed bolts and the like can often be coated without the need for masking as would be required in the case of powdercoating. Due to the baking temperatures, all materials processed must be able to withstand around 200°C.

Why Choose Us?

  • The only large-scale E-coating plant north of Melbourne.
  • Access to a world-wide E-coating knowledge base.
  • In-house quality and testing team.
  • In-house corrosion testing facilities.
  • One to one million component capabilities, with the ability to do custom and coloured E-coating work.
  • A true ‘one-stop-shop’ for all your coating needs.

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Automotive Applications

The use of E-coating pretreatments is largely responsible for eliminating rust in modern cars.

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Mining
Applications

E-coating can significantly increase the longevity of metal components used in harsh mining environments.

Electronics

Switchgear
Applications

E-coating finishes can significantly increase switchgear’s ability to function correctly in severe operating environments.

More on E-coating

Thickness: 5-25 microns (subject to end use).

Uniformity: Very uniform.

Hardness: Pencil Hardness H or harder.

Wear resistance: Paint-like, subject to product formulation.

Gloss: From clear/wet look to matt films (subject to volumes).

Colours: Currently running semi-gloss black RAL 9005. Can be changed for large orders.

Flexibility: Similar to paint-type coatings.

Toxicity: E-coatings are not approved for food contact applications.

Corrosion resistance: Black primer grades have excellent corrosion resistance, with correctly pretreated products withstanding 1000 hours of salt spray testing.

Chemical resistance: Generally, the stock black e-coat products have very good chemical and solvent resistance.

Standards: There are long established Australian and international standards for e-coating both steel and aluminium products.

Conductivity: E-coat, being an organic, paint-like coating, is non-conductive and can be masked off in areas if required.

Cost: If processed in volumes with our standard black interior coating and with special racks, it can be one of the cheapest finishes available. Special exterior clear coatings can greatly increase prices. Our charges will be subject to a number of factors such as volumes, processing conditions, and rack requirements. Like many of our processes, the labour for racking, un-racking, inspection and packing play a very significant part in our overall charges. Please contact us to find out more.

Size limitations: Impreglon can E-coat parts up to 2800 mm long by 1100mm high by 450mm wide.

Recommended Uses

E-coating is a very specialised coating that can resolve many problems in the finishing of products. With this said, the need for special racking and large volume production runs means it is not suitable for all type of work.

Before we process any work, we will always provide a specification or a service requirement for the E-coating so we can ensure our process meets all your needs, no matter how great or small.

Download our E-coating Fact Sheet

Want more information, or prefer to download something to read later? No problem at all.
Here’s a downloadable .pdf document that covers off all of our service details so that you can read more or share it with a colleague.

IMPREGLON E-COATING FACT SHEET.PDF

E-coating Case Study: Toyota Engine Mounts

Harringtons was looking to E-coat some key engine mounting components. Their challenge was that there was no one in New South Wales who could coat these components. At least, not yet…

READ MORE

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