Presentasi Electrodeposit Coatings

Understanding the
Basics of Electrocoat
Kelly Moore
Development Chemist
Overview
Why and When to Use Electrocoat

How Does Electrocoat Work?
Selecting the Right Electrocoat Technology
The Future of Electrocoat
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FABTECH Canada 2014 FINISHING Conference
Why and When to
Use Electrocoat
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Why Use Electrocoat?
Economical Environmentally Excellent Some

& Efficient Conscientious Performance Disadvantages
High transfer efficiency No or low VOC Controlled uniform film Capital expenditure
thickness
Precise film build HAPs-free products Color flexibility
control available Improved aesthetics (multiple colors)
100% coverage of Heavy metal-free No runs, drips, or sags Substrate must be
complex parts products conductive
100% coverage
Coats recessed areas Minimal waste Bake required
discharge One or two coat (thermoset)
Automated system: applications for optimal
low maintenance and Reduced fire hazards performance
minimal labor
Reduced exposure of Epoxy-based for
Dense racking of parts workers to hazardous corrosion, acrylic-
materials based for durability
Non-uniform line
loading
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0 FABTECH Canada 2014 FINISHING Conference
Selecting the Right Coating System
Performance Appearance
Requirements & Physical properties & durability (adhesion, flexibility, chip
Specifications resistance, corrosion resistance, UV resistance, etc.)
Substrate & Heat limitations

Part Configuration Part complexity and size
Environmental Air emissions (VOC/HAPs)

Factors Waste considerations
Economics – Transfer efficiency

Applied Cost Per Labor/time requirements
Square Foot
Number of parts to process
1
Selecting the Right Coating System
Liquid Powder E-Coat
Colors / Color Changes Best Better Limited

Heat Limitations Best Limited Limited
Environmental Impact High Lowest Low
Transfer Efficiency Limited Better Best
Manual Labor High High N/A
Automated Labor Good Good Best
# Parts Processed Limited Limited Best
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How Does Electrocoat Work?
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What is Electrocoat?
Method of applying a coating which

uses electrical current to deposit
aqueous dispersed resins and
pigments onto a conductive
substrate
• Highly efficient and automated process
• Precipitation of paint particles at
an electrode
• Paint film thickness is regulated
by voltage
1
The Deposition Sequence
• Voltage is applied and current flows between electrodes

• Water decomposes at the electrodes
• Paint particles move to the oppositely charged electrode
• Paint particles precipitate
• Paint particles become tightly packed (insulated)
• Deposition stops automatically
The insulating ability of the deposited wet film is what

allows the electrocoat process to coat interior recesses
and cavities – throwpower
1
Electrocoat Works Like a Magnet
Cathodic Anodic
Metal
Substrate
Cathode Anode
Coating film Paint Coating film
deposits Particles deposits
with FE++ without FE++
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Electrocoat Process:
The E-Coat Bath
Water-Soluble Bath Blend
Pigment
1-10%
De-Ionized Water
80-90%
Resins
10-15%
Solvent / Additives
1-5%
1
Sample Process Layout
Particle Filter Ultrafilter Racking
Flash (Pre-bake)
Oven
Pumps
Sample Tank Stages

Power Supply / • Cleaning
Process Control • Pretreatment
• Rinsing
• E-Coat
• Permeate Rinsing
1 • DI Rinsing
Pretreatment
Pretreatment
Without Pretreatment With Pretreatment
Rinse
• Cleans the metal and prepares it for coating

• Common to all application technologies
• Can be spray or immersion applied
• Major contributor to system performance
• Type and number of stages dictated by
performance requirements
1
The Electrocoat Tank
Electrocoat
Filter removes Permeate
dirt particles
Rinse
Circulation pumps and eductors
to ensure paint mixing uniformity
Ultrafilter produces
permeate for rinsing
and allow for recovery
of paint solids Electrocoat tanks may
Rectifier provides DC hold up to 100,000 gallon
electrical charge; heat
exchanger controls bath
temperature
2
The Post Rinse & Bake Oven
1 - 3 counter-flowing rinses remove
excess paint solids
Smoother finish appearance
Higher operating efficiency
Used to cure and crosslink the paint film

Bake varies from 180º F - 375º F
depending on electrocoat type
Usually require at least 10 - 20 minutes
metal temperature for full cure
2
Equipment Design and Operation:
Selection Criteria
Capital Expense Floor Space Productivity
Maintenance Racking Process

of Parts Flexibility
2
Monorail Systems
• Highest productivity • Biggest footprint
• Lowest maintenance • Highest capital expense
2
Programmable Hoist System
• Highest flexibility • Highest maintenance
• Medium to low capital expense • Lowest productivity
• Smallest floor space
2
Square Transfer System
• Lowest capital expense • Medium to low maintenance
• Smallest floor space • Medium to high productivity
• Medium flexibility
2
Racking vs. Bulk Electrocoat
Racking Bulk
• Part configuration / design • Dip-drain / sip-spin
• Size / number / density of parts • Shift parts to coat touch points
• Touch points on parts • Fasteners, other small parts
• Maintenance
2 • Contact points
Relative Comparison of Systems
Indexing System
Programmable Monorail
Hoist Square Transfer
Productivity Lowest Medium to High Highest
Maintenance Highest Medium to Low Lowest
Capital
Medium to Low Lowest Highest
Expense
Floor Space Small Smallest Highest
Process
Highest Medium Lowest
Flexibility
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Selecting the Right
Electrocoat Technology
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Electrocoat Types
Paint particles positive Paint particles negative

Coated parts negative Coated parts positive
Advantages Advantages
Less iron incorporated Economical systems
into the film for interior or moderate
exterior environments
Formulated for
maximum corrosion Low cure temperatures
resistance and exterior
durability Low VOC
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Electrocoat Technologies
Advantages Disadvantages
Corrosion protection Poor U.V. resistance (chalks)
Chemical resistance Poor color stability (cationic)
"Tough" film
Advantages Disadvantages
Good U.V. resistance Less corrosion protection
Gloss retention
Good color control
3
Benchmark for corrosion & Low-bake applications

chemical resistance Heavy-duty castings,
Automotive parts, car compressors
bodies, heavy duty trucks,
fasteners
High performance, Color & gloss control for

one-coat applications interior products
UV durability Metal office furniture, air
& detergent resistance diffusers, range hoods,
tool boxes
Color control
3
Excellent corrosion resistance, especially on sharp edges

Lead-free
HAPs-free
Low VOC
• Agriculture & • Engine cradles • Switchgear

construction • Heavy duty trucks • Torsion bars
• Automotive parts • Marine engines • Transformers
• Compressors • Spring clips • Truck frames
• Computer parts • Suspension
• Control arms components
3
Low cure: 180-225º F cure capability

Fully thermoset
Hardness/corrosion resistance similar to higher cure coatings
Lead and chrome-free
Good throwpower
More iron in film, which limits performance
• Agricultural implements • Construction equipment • Pipe

• Assemblies fork lifts • Engines & motors • Plated plastics
• Compressors • Seat tracks • Structural steel
• Concrete • Heavy duty castings • Aluminum substrates
reinforcements • Military aircraft • Galvanized substrates
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High performance with both high- and low-gloss capability

Color control and can be formulated as a clear
Can be formulated for optimum corrosion or durability
HAPS compliant
Topcoat-able (should be tested)
• Agricultural implements • Heavy duty equipment • Welding equipment

• Air conditioners • Lawn & garden • Wheels
• Aluminum extrusions • Refrigeration
• Appliances • Switchgear
• Brass, plated substrates • Transformers
3
Excellent appearance, gloss, and color control

Interior & mild exterior use
Reduced emissions
No/low solvent additions
No heavy metals
More iron in film, which limits performance
• Air conditioners • Metal strapping

• Air diffusers • Range hoods
• Furnaces • Toolboxes
• Hangers • Wire screen
• Metal office furniture
3
Electrocoat Applications
Electrocoat is the final finish
Two electrocoat layers for high performance
Electrocoat + a liquid or powder topcoat produces

exceptional performance properties
3
Cathodic epoxy basecoat ensures excellent

corrosion protection
Cathodic acrylic primer-surfacer provides an exterior
durable finish and cost-effective topcoat
Corrosion protection, chip resistance, UV durability
No heavy metals
• Agricultural implements • Marine engines

• Aluminum trim • Transformers
• Condensing coils
• Generator housings
3
Cathodic epoxy basecoat ensures excellent

corrosion protection
Liquid or powder topcoat allows for combination of corrosion
resistance and desirable appearance
• Automotive
• High-end appliances
• Sports and recreation
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Summary
Corrosion Resistance
Auto Parts
Low Cure
Coat Hangers • Shopping Carts
UV Resistance
Washers & Dryers • Lawn & Garden • Agricultural Equipment
Decorative
Consumer Electronics • Jewelry
Severe Environments
Generators • Transformers
Performance + Appearance
Automotive • Appliances • Sports and Recreation
3
Questions?
4
Thank You
Kelly Moore
Development Chemist
PPG Industrial Coatings
1-800-774-3262
ecoatinfo@ppg.com
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Understanding the

Why and When to Use Electrocoat

Economical Environmentally Excellent Some

Substrate & Heat limitations

Environmental Air emissions (VOC/HAPs)

Economics – Transfer efficiency

Liquid Powder E-Coat

Colors / Color Changes Best Better Limited

Method of applying a coating which

• Voltage is applied and current flows between electrodes

The insulating ability of the deposited wet film is what

Water-Soluble Bath Blend

Sample Tank Stages

• Cleans the metal and prepares it for coating

Used to cure and crosslink the paint film

Capital Expense Floor Space Productivity

Maintenance Racking Process

Productivity Lowest Medium to High Highest

Maintenance Highest Medium to Low Lowest

Floor Space Small Smallest Highest

Paint particles positive Paint particles negative

Benchmark for corrosion & Low-bake applications

High performance, Color & gloss control for

Excellent corrosion resistance, especially on sharp edges

• Agriculture & • Engine cradles • Switchgear

Low cure: 180-225º F cure capability

• Agricultural implements • Construction equipment • Pipe

High performance with both high- and low-gloss capability

• Agricultural implements • Heavy duty equipment • Welding equipment

Excellent appearance, gloss, and color control

• Air conditioners • Metal strapping

Electrocoat is the final finish

Two electrocoat layers for high performance

Electrocoat + a liquid or powder topcoat produces

Cathodic epoxy basecoat ensures excellent

• Agricultural implements • Marine engines

Cathodic epoxy basecoat ensures excellent

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