Powder Coating Aluminum: The Complete Guide

Everyone knows about coating. As it is obvious coatings have various types. Similarly powder coating is one of the common powder coating techniques. If you are not sure about, is it suitable to choose powder coating technique for your Aluminum (Al) product, or want to know can aluminum be powder coated, then this article will help you understand every basic knowledge of powder coating of aluminum. After reading this you will surely know why to select powder coating and how this will help you in any project.

What is Powder Coated Aluminum?

It is a normal aluminum-based product which has been subjected to coating made of different resin and polymer. This helps in providing improved designs, corrosion resistance and durability to aluminum material and extrusion. Powder coating is very famous for Al extruded products. It is applied same as the spray paints. The purpose is to provide a better finish and color to the final product for adding a decorative element in it. It also adds corrosion resistance and wear resistance to product and helps in maintaining the properties and features for long time.

What is the Aluminum Powder Coating Process?

Electrostatic spray deposit method is used to apply powder coating on aluminum. A powder spray device is utilized to precipitate the coating particles over the Al. Coating material is made of various polymers such as epoxy, acrylic, polyurethanes which are added with pigment, flow modifier, curing agent, and additive. These are added to make sure that coating material is applied evenly over the product. The process is based on five steps:

1. Pre-treatment

Aluminum products are subjected to pre-treatment baths to clean the impurities, and grease. This step is essential for correct adhesion of coating over the product.

2. Powder coating spray

Electrostatic powder spray booth is used to coat the aluminum product. particles are bonded electrically over the product having a positive charge ion.

3. Curing

Aluminum product is cured in an oven to let the coating set evenly over the surface.

4. Cooling

The product is taken out of the machine and let it cool down at normal temperature in normal conditions and goes through a quality check for adhesion, thickness, scratch tests and punch tests.

5. Protective film application

A protective layer is applied all over the material to make it scratch free and to avoid it from any damage.

Can you Powder Coat Aluminum?

Yes, aluminum can be powder coated. It is one of the famous powder coating techniques carried out for aluminum products. It adds corrosion resistance and wear resistance and durability. Furthermore, it is used to add decorative elements in the aluminum product due to good aluminum surface finish.

How to powder coat aluminum?

Powder coat on aluminum is done in five steps: these are pre-treatment bath, powder spray coating, curing, cooling, and adding protective film over the aluminum product.

Powder coating thickness on aluminum

Standard powder coat on aluminum has thickness usually ranged from 60-80microns which is 2-3miles. The standard metric measurement unit for powder coating process is microns and 25.4microns=1mil.

Powder Coating Colors on Aluminum

Aluminum powder coating process has variety of colors for aluminum surface finish. The color ranges normally include blue, silver, grey, orange, white, red, yellow, black, and etc. powder coat on aluminum products depends on customer and project requirements.

Finishes for aluminum surfaces

Aluminum surface finish obtained from aluminum powder coating process is smooth, glossy, shiny and different in colors. Other aluminum surface finish processes include machine finishing, anodizing, dip coating, liquid paint coating, and sublimation.

Advantages of Powder Coating Aluminum

Powder coated aluminum has many benefits. Some of them are:

Variety in designs: coating gives a stylish appearance to the material. It is also available in different colors, thickness, matte or shiny, coarse grain, or fine grains. These all factors add sleek look to the product. That is why it is mostly preferred for decorative purposes.

Durability: it is preferred for outdoor application on aluminum products. This coating has high corrosion resistance, wear resistance and durability. However, if the process is not carried out according to instructions, the coating can be damaged by physical hazards outdoors.

Environmentally friendly: powder coating process does not contain any volatile compounds that can be hazardous to health or environment. It is safe to be used in indoor applications as well because of almost no emissions.

Cost effective: powder coating technique is very economical as compared to other coating processes. The polymer and resins used are readily available. Furthermore, the overall process is not so expensive including machines and labor costs.

Corrosion resistance: powder coat on aluminum increases corrosion resistance which makes it suitable for harsh environment applications. Aluminum itself has high corrosion resistance and powder coat on aluminum further adds to its resistance.

Disadvantages of Powder Coating Aluminum

Aluminum powder coating process also has some disadvantages. These are:

1. Not suitable to be used near to UV-rays.
2. It is difficult to change its color.
3. Control over the process variables is difficult like speed and amount.
4. Variety of machines required to carry out the process.
5. Electrostatic procedures must be carried out to coat the product.
6. Relatively longer processing time
7. Costly to initiate the process.
8. Smoothness must be controlled during the process to make the part rust free.

Powder Coated Aluminum Application

Does powder coated aluminum rust

Yes, powder coated aluminum is rust-free. Polymer ingredients enhance the corrosion resistance of coated products. However, if the process is not carried out according to directions, there is a chance that corrosion might occur in harsh conditions.

Powder coated aluminum patio furniture

Aluminum Powder coating has high toughness with its light weight. It is best suited for outdoor applications like patio furniture. It has a pleasant appearance with high strength.

Powder coated aluminum fence

Aluminum surface finish has no to little cracks or do not peel off when it is used outdoor as fences. It has higher quality than normal paints. A powder coated aluminum fence has wrought iron looks but it has no maintenance and is aesthetically pleasant.

Does powder coating weaken wheels

Powder coating technique on wheels influence the strength and performance. It weakens the structure and the heating level during process affects the cast or forged wheels.

Powder coated valve covers

Common issue often occurs in the valve cover that coating starts peeling off, but the powder coated valve covers has high durability, strength, and corrosion resistance. it does not peel off easily and has long life than normal coatings.

Powder coated aluminum gates

Polyester based coating on aluminum parts increases corrosion resistance. powder coated aluminum gates have long life and strength and can withstand outdoor environments.

Best Coating for Aaluminum

Powder coating has high corrosion resistance, toughness and on aluminum it is light weight with high strength. The durability of aluminum powder coating is longer than the normal coatings. It is cost effective and environmentally friendly for outdoor applications. It is also suitable for indoors applications like for kitchen appliances and decoration items providing aluminum surface finish a smooth, textured, and pleasant color look.

Brushed aluminum powder coat

Brushed aluminum has high corrosion resistance when powder coated. It is also pleasing aesthetically, and surface finish is extremely smooth. It is cost-effective method and has high durability than other coatings. Abrasion and wear resistance are high which makes it good for heavy traffic applications. It is environmentally friendly coating has cannot be easily chipped off.

Powder coating cast aluminum

Cast aluminum can be powder coated. It is one of the coatings that has high versatility and extra durability with long-lasting features. The colors and textures of aluminum powder coated products is smooth and shiny.

Anodized aluminum vs powder coating

Powder Coating vs Other Coating Methods

Powder coating has many features that are comparable to other coating techniques. This comparison is explained in the table.

Fluidized Bed Powder Coating

A coating process in which fine grounded powder is first suspended in air. Then, they are preheated and soaked into powder bath. The melted powder is then applied to the product and provides a smooth finish all over the part. It has a thick coating layer over the metal. This coating helps in concealing little defects in the material. the advantages of fluidized bed powder coating over other coatings are:

1. Smooth and uniform finish
2. Thick coating layer of 10-15mils
3. Remarkable wear, corrosion, chemical resistance
4. Can sustain harsh weather conditions.
5. Conceal little defects.
6. Non-conductive so electrical resistance is good.

Can you powder coat plastic?

Plastics like thermoplastics and thermosets can be powder coats. Thermoplastics coating has high heat resistance as compared to aluminum powder coating and has comparable durability, easy repair coating. Plastics have high resistance to cold, chemicals, and water therefore, this coating is ideal for outdoor applications. Powder coating on plastics adds decorative element thus, they are normally done on outdoor furniture.

Industrial Powder Coating Aluminum

Powder coating aluminum has great demands in industries. It provides remarkable feature to extruded aluminum products which makes it suitable for industrial applications. The features enhanced in extruded aluminum products are:

1. High wear resistance
2. UV resistance
3. Electrical resistance
4. Easy repair
5. Easy cleaning
6. Smooth texture
7. Glossy finish
8. Variety in colors

Substrate Considerations

Some issues occur in substrate when carrying out powder coating on aluminum. These are poor charge, lack in wrapping, low layer building, and poor penetration of powder. These can create a grainy look over the finished surface and can peel off during service life. low film building can reduce the surface smoothness and actual colors are not so enhanced in final products. Poor penetration occurs when the part has irregular geometry or has internal corners. The electrostatic current travelling effects and powder is not applied evenly over the surface. Therefore, considerations must be applied before carrying out the process to avoid these challenges in powder coating process.

Cost and Choosing a Service Provider

Powder coating costs up to $20-25/sq.ft. But this cost can differ and depends on service providers. If you are looking for a reliable provider for powder coating on aluminum, Tuofa offers a variety of surface finish processes for aluminum powder coating. Toufa CNC machining provides manufacturing and rapid prototyping services. It offers on demand and custom services for CNC machined parts, 3D printing, sheet metal custom for our customer. Surface finishes like powder coating, anodizing and electroplating are also provided at TOUFA. For more information please visit: https://www.tuofa-cncmachining.com/

Conclusion

Aluminum can be powder coated. It is one of the famous powder coating techniques carried out for aluminum products. It adds corrosion resistance and wear resistance and durability. Furthermore, it is used to add decorative elements in the aluminum product due to good aluminum surface finish. Powder coating has high corrosion resistance, toughness and on aluminum it is light weight with high strength. The durability of aluminum powder coating is longer than the normal coatings. It is cost effective and environmentally friendly for outdoor applications.

Powder Coating Aluminum Problems

Common issues occur in powder coating aluminum are:

1. Color matching
2. Corrosion
3. Peeling or inclusion
4. Coating fails to stick.
5. Chalking

How to remove powder coat from aluminum

Powder coats can be removed from aluminum by a solvent chemical, using heat guns, or by a gasket remover.

How to clean powder coated aluminum railings

Powder coated aluminum railing can be cleaned by adding liquid detergent in water and by gently rubbing over the surface. It has easy maintenance and cleaning by simple microfiber clothes.

How to clean powder coated aluminum patio furniture

Mild liquid detergent and water can be added and by gently rubbing over the aluminum powder coated patio furniture can remove any dirt.