Complete Guide To: Powder Coating Aluminum

Spray Powder Coat On Parts

Powder coating is a durable, long-lasting, protective finish for metal parts. Unlike most protective surface finishes, powder coating uses a free-flowing dry powder. It is part of dry-finishing process and can be sprayed on materials or applied using tanks. 

Powder coating offers many benefits, colors, and textures. In this blog, you’ll learn the powder coating process, why aluminum parts are powder coated, and how it compares to anodized aluminum.

What Is a Powder Coat?

A powder coat is the layer that forms after the powder coating process. Powder coated layer is the cured, coating made up of dry powder (resin) and pigment. It is tough, protective, durable, and contains a resin that produces texture on the metal part.

Aluminum Powder Coated Springs

Aluminum Powder Coating Process

Powder-coating aluminum is a multi-step process that controls the pigment, thickness and curing. It can be broken down into smaller steps

Aluminum Surface Cleaning

The aluminum part that is to be coated is thoroughly cleaned to remove any corrosion, dirt, cutting fluid, and grease. In addition, any oxide layers and protective coatings like anodized layer should also be removed. Aluminum surface preparation is important because any remaining oil can interfere with the powder coat, and the part’s surface may not be coated. 

Generally, aluminum products are cleaned using degreasers and etching chemicals but some parts also require sandblasting. Dirt and grime can result in layer peeling and bubbles in the powder-coated aluminum.

Dry Powder Application

The dry powder is a mixture of pigment (color), additives, and ground resin. The additives in a powder coat are levelers, flow modifiers, and curatives. The mixture is prepared and there are two ways to apply powder coat. 

Spraying

The dry powder is loaded into a spray gun which uses compressed air to shoot electrostatically charged particles on the aluminum surface. The grounded aluminum part attracts the positive electrostatic powder and coats it evenly. 

For large parts and panels, powder particles can be more easily applied using a spray gun. A base coat can be applied to cover the aluminum parts and then another layer to cover any hard-to-reach areas.

Spraying Powder Coat

Dipping (Fluidized Bed)

Small parts can be dipped into dry powder tanks. Dipping is not an electrostatic process and a pretreatment process, specifically pre-heating the part between 175° – 230°C allows the dry powder to melt on the surface of the aluminum and stick to it. 

The dry powder tank cycles air through the tank and keeps shaking and moving the coating powder.

Removing Aluminum Part After Dry Finishing

Curing

The most important part of the process of powder coating is curing. In the curing process, the freshly powder-coated aluminum part is placed inside a curing oven at around 200° to form a tough solid layer. Curing time and temperature affect the thickness and quality of the powder coat.

Durability of Aluminum Powder Coat

The aluminum powder coat offers a durable finish that can withstand demanding environments. Powdercoat protective layer is ideal for harsh conditions and impacts. It can resist UV damage, and chemical exposure, ensuring coated parts are protected for a long time. 

Powder-coating aluminum parts make them more wear-resistant against chips, scratches, and abrasions. 

Powder coating comes in various colors and lasts longer than normal paint. Powder coatings are also tested to ASTM standards like ASTM G154 against weathering, for resilience for long-term performance. 

Aluminum Powder Coating Colors

Aluminum powder coating offers a vast range of colors. It is both an aesthetic and functional protective layer. Standards like RAL provide color matching through thousands of selections for aluminum wheels and components in bike frames. 

Common powder-coating aluminum colors include matte, textured, high gloss, satin, and options like black, white, gray, yellow, bronze, blue, green, etc. 

Aluminum powder coating also offers different texture finishes like smooth or grained effects. Different types of powders offer wide catalogs and a precise selection of coat application.

Textured Finish On Wheels

Advantages of Powder Coating

Durability

Powder coating applies a tough, protective layer with adjustable coating thickness. Powder coat can withstand UV rays making it a good aluminum finish for outdoor applications. The resin is also weatherproof and acts as a barrier against water and harsh weather.

Environmentally Friendly

Unlike other types of protective finishes, dry powder does not release any volatile organic compounds (VOCs) and any extra uncoated particles or overspray can be reused. 

Aesthetic

The powder coat has good adhesion and you can achieve a high-quality finish with no pores, or peels and achieve different textures from gloss and matte to metallic or wood grains.

Cost-effective

Powder coating saves costs in the long run. Most parts are powder-coated for color and protection and powder-coated parts outlast painted surfaces. It saves repainting costs, and is more efficient for multiple coatings. 

Corrosion Resistant

Aluminum is naturally corrosion resistant, but powder coating adds an extra layer of protection that increases the corrosion resistance of the aluminum part.

Powder Coating VS Anodizing

Powder coating finish and anodizing are both aluminum finishing processes. Powder coating sprays a dry electrostatically charged powder to coat the aluminum surface and anodizing is an electrochemical process that grows an oxide layer from the surface of the aluminum. 

Anodizing offers tougher, harder protection with higher corrosion resistance. However, anodizing is more expensive than powder coating and offers limited texture options.

Powder Coating Service | Prolean-Tech

Are you looking for a durable, vibrant powder coating that can protect your aluminum parts? Contact Prolean-tech today for top-quality powder coating solutions tailored for your specific needs. 

Upload your design for a quick quote. 

Key Takeaways For Your Powder Coating Aluminum Project

Powder coating aluminum is ideal for parts that need color consistency, wear resistance, and gloss finishes. It also offers vibrant colors and an aesthetic appeal. Using a powder coat it is possible to change the texture of the aluminum surface without chemically altering its nature like electrochemical processes. 

It is cost-effective, free of toxic or carcinogenic compounds, and offers a smooth finish. This all there’s to know about powder coating and you can explore more aluminum finishing options.

FAQ

• Does powdercoat work on aluminum?

Powder coat adheres to aluminum surface and is better than liquid paint. 

• How long does powder coating last on aluminum?

Powder coating on aluminum can last for years. It has excellent resistance to corrosion and abrasion prolonging part life. The coat itself can last between 5 to 30 years depending on use and environment.

• How do you powder coat aluminium?

You can powder coat your aluminum part using an electrostatic spray gun and compressed air to spray powder on grounded aluminum part. 

• Is powder coated aluminium good?

Powder coating increases the durability of aluminum and protects it from scratches and daily wear.