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Al-Zn Flake Coating

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Al-Zn Flake Coating

Aluminum-Zinc (Al-Zn) flake coating is an advanced corrosion protection system used primarily for metal components. It consists of aluminum and zinc flakes dispersed in a binder, forming a protective layer that provides exceptional corrosion resistance without the need for electroplating.

This coating is applied through a dip-spin or spray process and then cured at a high temperature, creating a thin, dry film that acts as a barrier against oxidation and environmental damage.

Key Benefits of Al-Zn Flake Coating
  • Superior Corrosion Resistance – Protects against red rust for over 1000+ hours in salt spray testing (ASTM B117).
  • Eco-Friendly & Chromium-Free – Free from hexavalent chromium (Cr6+), making it safer for the environment and compliance with RoHS and REACH regulations.
  • Thin, Lightweight Coating – Provides excellent protection without adding bulk to metal components.
  • Heat & Chemical Resistance – Withstands high temperatures and exposure to harsh chemicals.
  • No Hydrogen Embrittlement – Unlike electroplating, it eliminates the risk of hydrogen embrittlement, making it ideal for high-strength fasteners and springs.
  • Excellent Adhesion & Recoatability – Can be combined with topcoats for additional protection and customization.
Common Applications
  • Automotive Industry – Bolts, nuts, fasteners, brake components
  • Aerospace & Defense – Structural components, aircraft parts
  • Construction & Infrastructure – Bridges, steel structures, reinforcement bars
  • Heavy Machinery & Marine – Equipment, offshore structures, ship components
Application Process
  • Cleaning & Surface Preparation – Parts are degreased and cleaned.
  • Coating Application – Applied via dip-spin, spray, or brush methods.
  • Curing – The coated parts are heated at high temperatures to form a strong, bonded layer.
  • Inspection & Quality Check – Parts undergo testing to ensure durability and performance.
Why Choose Al-Zn Flake Coating?

It is a cost-effective, long-lasting, and environmentally friendly alternative to traditional plating and galvanization, making it ideal for industries where high-performance corrosion protection is crucial.

Would you like more details on specific aspects like testing methods, suppliers, or technical specs?

Paint Base

Paints are broadly categorized based on their solvent composition and application methods. Here's an overview of water-based paints, solvent-based paints, and topcoats:

​Water-based paints, commonly known as latex paints, utilize water as the primary solvent to disperse pigments and binders. They are favored for their quick drying times, low odor, and ease of application. Additionally, these paints emit fewer volatile organic compounds (VOCs), making them an environmentally friendly choice for both interior and exterior surfaces.

Solvent-based paints, often called oil-based or alkyd paints, use organic solvents like mineral spirits as carriers for pigments and binders. They provide a durable, glossy finish resistant to wear, making them suitable for high-traffic areas and exterior surfaces. However, they emit higher levels of volatile organic compounds (VOCs), necessitating proper ventilation during application.

A topcoat is the final layer applied over paint or stain to seal and protect surfaces from wear, moisture, and UV damage. It enhances durability, provides resistance to abrasions, and offers desired finishes like glossy or matte, thereby preserving the underlying material and extending the lifespan of the paintwork.

Comparison Chart: Hot Dip Galvanizing vs. Zinc Plating vs. CED Coating vs. Zn Flake Coating
Parameter Hot Dip Galvanizing (HDG) Zinc Plating (Electroplating) CED Coating (Cathodic Electro Deposition) Zn Flake Coating (Al-Zn Flake Coating)
Process Dipping steel in molten zinc Electrochemical deposition of zinc Electrophoretic deposition of organic coating Application of zinc-aluminum flakes in a binder
Coating Thickness 50-150 µm 5-25 µm 15-25 µm 5-20 µm
Corrosion Resistance Excellent (1000+ hrs SST) Moderate (24-96 hrs SST) Good (500-800 hrs SST) Superior (1000-3000+ hrs SST)
Hydrogen Embrittlement No Yes (risk for high-strength fasteners) No No (suitable for high-strength components)
Heat Resistance Moderate (up to 200°C) Low (up to 120°C) Moderate (up to 180°C) High (up to 300°C)
Wear Resistance Good (thick coating) Poor (thin coating, prone to chipping) Moderate Excellent (hard, durable layer)
Adhesion to Base Metal Strong Moderate Very Strong Strong
Eco-Friendly (Cr6+ Free) No (produces zinc fumes) No (Cr6+ presence in some cases) Yes Yes (RoHS & REACH compliant)
Aesthetic Finish Rough & Matte Grey Bright & Shiny Smooth & Glossy Matte, Silver/Grey Appearance
Common Applications Structural steel, bridges, poles, heavy-duty parts Fasteners, bolts, small parts, decorative items Automotive bodies, electronics, appliances Automotive, aerospace, fasteners, high-strength components
Advantages of Zn Flake Coating (Al-Zn Flake Coating)

Zn flake coating is widely used in automotive, aerospace, construction, and industrial applications due to its exceptional performance in corrosion protection and durability. Here are its key advantages:

1. Superior Corrosion Resistance

  • Provides 1000–3000+ hours of protection in salt spray tests (ASTM B117).
  • Forms a barrier layer that prevents oxidation and corrosion, making it ideal for harsh environments.

2. No Hydrogen Embrittlement

  • Unlike zinc electroplating, Zn flake coating does not introduce hydrogen embrittlement, making it safe for high-strength fasteners, bolts, and springs.

3. High Heat Resistance

  • Can withstand temperatures up to 300°C (572°F) without degradation, making it ideal for engine components, aerospace parts, and exhaust systems.

4. Thin, Lightweight Coating

Provides effective corrosion protection with a thin layer (5-20 µm), ensuring:

  • No dimensional changes in precision components.
  • • Suitable for threaded fasteners without affecting fit.

5. Excellent Adhesion & Recoatability

  • Strong adhesion to metal surfaces, allowing additional topcoats or sealers for enhanced performance.
  • Compatible with organic and inorganic topcoats, improving wear and chemical resistance.

6. Eco-Friendly & Compliant

  • Chromium-Free (Cr6+ Free) – Meets RoHS, REACH, and ELV regulations, making it a sustainable alternative to traditional coatings.
  • Lower environmental impact compared to hot-dip galvanizing or electroplating.

7. Chemical & Wear Resistance

  • Resistant to chemicals, oils, fuels, and cleaning agents, extending component life in industrial and automotive applications.
  • Provides abrasion resistance, making it durable in high-friction environments.

8. Suitable for Complex Shapes & Small Parts

Can be applied using dip-spin or spray processes, ensuring even coating on:

  • Small fasteners (nuts, bolts, screws).
  • Intricate parts (springs, clips, brackets).
    Ensures uniform coverage even in hard-to-reach areas.

9. Cost-Effective Alternative to Galvanizing

  • Less material usage compared to hot-dip galvanizing.
  • Lower maintenance costs due to extended component life.