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Cathodic Dip Coating (E-Coating)

Cathodic Dip Coating (E-Coating)

If you would like to finish a large number of workpieces or complex constructions with corrosion and impact-resistant coating, cathodic dip coating (CDC or E-Coating) is a solution you should consider. Regarded as one of the most efficient coating processes, cathodic dip coating is ideal for metal surfaces used in industrial applications. Using automated CDC coating processes, it is possible to achieve uniform layer thicknesses and good surface qualities on metal surfaces and in cavities.

Cathodic dip coating is also called E-Coating, which stands for electrophoretic coating and refers to the same process. Since it mainly uses water-based solvents, the E-Coat process is particularly eco-friendly.

During the CDC process, the workpiece to be coated is negatively charged and immersed in a paint bath containing positively charged paint particles which are attracted by and deposited onto the workpiece. The particles contained in the paint bath form a uniform coating on the entire surface. Thus, every single crevice and edge will be coated in the specified thickness. The film will insulate the component and thus stop the electric attraction. Once the CDC coating has been applied, it will be cured in the furnace at temperatures between 180 and 220°C for final sealing.

Cathodic dip coating eco-friendly corrosion protection

Cathodic dip coating (E-Coating) is a very eco-friendly surface coating process, because it usually involves the use of water-based solvents. Thanks to the innovative technology of our high-performance plants, the paint yield is almost 100%.

Are you faced with similar challenges? Aalberts surface technologies offers many possibilities for customizing its E-Coating processes to your specific requirements.

One of the major advantages of cathodic coating processes is the uniform coating of metal surfaces and cavities with very even coating thicknesses and good surface qualities. Dip coating as cathodic corrosion protection offers effective and long-lasting corrosion protection with a high resistance to temperatures and chemicals. Cathodic dip coating is scratch-proof and offers protection against stone chips. What is more, CDC processes are eco-friendly coating methods, because they usually involve the use of water as a solvent. They are ideal for automated coating and conform to the high standards applicable to coatings in the automotive industry.

Cathodic dip coating

During the cathodic dip coating process, the negatively charged workpiece is immersed in a paint bath containing positively charged paint particles. Attracted by the workpiece, these particles form an even layer on the entire surface. Once the protective E-Coating has been applied, it will be cured at temperatures between 180 and 220°C.

The advantages of cathodic dip coating (E-Coating):

  • Even cavities which are difficult to access as well as sharp edges and thin joints will be coated with a highly adherent and even layer
  • Short immersion times (a few seconds)
  • Excellent scratch and impact resistance
  • Excellent corrosion protection
  • High quantities
  • Electrically insulating

Cathodic dip coating is applied to components made of the following materials:

  • Aluminum alloys
  • Non-ferrous metals
  • Ferrous materials (steel)
  • Magnesium alloys
  • Titanium materials
  • Zinc die-casting

In the automotive industry, components are pre-treated in cathodic dipping baths with the aim of protecting them against rust and corrosion. Apart from that, cathodic dip coating is a suitable primer for conventional coatings or powder coatings. Especially commercial vehicles benefit from this type of coating, as it makes them more durable and robust.

In mining, CDC (E-Coating) ensures lasting durability when it comes to metal parts used in harsh environments. Plant engineering and switch cabinet construction as well as mechanical engineering (e.g. punched parts) are further industrial sectors that benefit from E-Coatings. Our electrochemical process has also proven its worth in the chemicals and sports industries.

In practice, Aalberts surface technologies's cathodic dip coating processes create surface finishes which prove their performance every day:

  • Components of wind turbines
  • Impact-resistant protective covers for rotating tools
  • Housings and covers for electronic systems and electric chain hoists
  • Temperature-resistant gas turbine guide vanes
  • Covers and back irons for very small engines

When used as Duplex coating, cathodic dip painting can also be applied to zinc flake, electroplated zinc or zinc alloy layers. CDC (E-Coating) can thus be used in almost any area, irrespective of the color and surface structure.

  • Are surface finishes created with cathodic dip coating processes environmentally friendly?

    Surface finishes created with cathodic dip coating processes are eco-friendly, because the used solvent is based on water and the coatings are free from lead and zinc.

  • Is it possible to combine CDC processes with other procedures?

    Coatings created with the E-Coating process can be used as top coats on galvanized sheet metal or individually galvanized components (where it is used for coloring or for increasing the components' resistance to corrosion).

    Coatings created with CDC (E-Coating) can be perfectly used underneath powder coatings. This layer structure (cathodic dip coating + powder) results in increased corrosion protection and visual improvement. This layer combination is often used in the automotive, commercial vehicles and agricultural machinery industries.

  • Why is Electrocoating the ideal coating solution for large numbers of workpieces?

    During the electrocoating process, the coating is applied by immersion, a process with virtually no paint loss, which is another advantage from an environmental point of view. This coating process creates thicknesses between 10-60 µm, which allows achieving different corrosion resistance classes.

    The process is suitable for complex geometries and hollow parts which are difficult to coat using spraying processes. CDC creates even layers and constitutes a cost-effective solution.

  • How does cathodic dip coating protect workpieces used in the automotive industry?

    Most of the time, this process is used for engine components whose resistance to corrosion is of the utmost importance. When coating components with CDC, it is possible to achieve excellent resistance to chemicals, which is important, for example, when it comes to radiator hoods or supports in engine compartments.

  • You are planning on finishing a large number of workpieces or complex constructions with corrosion and impact-resistant coating?

    Cathodic dip coating (CDC) or E-Coating is a process suitable for this purpose. It is regarded as one of the most efficient coating processes for industrial metal surfaces.

  • What is E-Coating?

    E-Coating stands for electrophoretic coating or electrocoating, which refers to the process where positively charged paint particles are deposited onto a negatively charged component to create a coating with a uniform film thickness on the entire workpiece surface.

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