Industrial-Grade High Corrosion Coating Solution
High Corrosion Coating is a non-electrolytically applied zinc-aluminum flake protective system engineered to deliver superior corrosion resistance on ferrous metal components. The coating forms a structured Zn-Al flake layer combined with binder and passivation chemistry to create a dense and durable protective barrier.
The system is designed for automotive, infrastructure, marine, and industrial applications where extended durability and high resistance against aggressive environments are required.
Advanced Corrosion Protection Mechanism
The protection mechanism is based on multiple functional layers working together:
Sacrificial Protection
Zinc flakes corrode preferentially, protecting the underlying steel substrate.
Barrier Effect
Uniformly aligned Zn-Al flakes block the penetration of water, oxygen, and salts.
Passivation Layer
Chemical passivation improves surface stability and enhances corrosion resistance.
Self-Healing Effect
Minor coating damage during handling is protected due to zinc’s sacrificial nature.
This multi-layered system significantly enhances long-term corrosion performance.
Key Features of High Corrosion Coating
- Thin coating thickness with high corrosion resistance
- No hydrogen embrittlement risk
- Reduced galvanic corrosion
- Environment-friendly coating process
- No wastewater generation
- Cost-effective alternative to Zn-Ni electroplating
- Suitable for small precision components
The coating is ideal for parts requiring long durability and components where hydrogen embrittlement is not permitted.
Performance Parameters
To achieve over 1000 hours Neutral Salt Spray Test (NSST), the coating must maintain:
- Minimum coating thickness: 8 microns
- Minimum coating weight: 240 mg
Uniform coating thickness and proper curing conditions are critical for achieving these performance standards.
Coating Process Overview
1. Surface Pretreatment
- Degreasing using alkali water rinse or solvent
- Shot blasting using stainless steel balls (2–4 mm depending on part size)
Proper substrate preparation directly impacts coating adhesion and corrosion performance.
2. Make-Up Process
The coating system consists of two components:
- Component #1: Inorganic zinc and aluminum dispersion
- Component #2: Organic binder
Make-up requirements include:
- Stirring of component #1 before mixing
- Temperature control at 20 ± 2°C
- Gradual addition of component #2 in two stages
- Slow dosing of thickener
- Minimum 8 hours agitation after thickener addition
Strict temperature and viscosity control ensures uniform coating thickness.
3. Application Methods
High Corrosion Coating can be applied using:
Dip-Spin Coating
- Most economical and widely used method
- Suitable for fasteners, screws, springs, clips, brackets
Dip-Drain Coating
- Used for larger steel components
Spray Coating
- Suitable for large parts where dipping is not feasible
4. Curing Process
- Pre-heating: 10 minutes at 160°C
- Curing: 25–30 minutes at 300°C
Controlled evaporation during pre-heating prevents flake disturbance. Over-baking or under-baking can reduce coating performance.
Quality Testing & Inspection
Each coated component undergoes strict evaluation including:
- Visual appearance inspection
- Salt spray corrosion test (ISO 9227 / ASTM B117)
- Coating thickness measurement
- Adhesion testing
- Cyclic corrosion testing
- MEK rub test (minimum 10 double rubs)
- Water resistance test (240 hours)
- Oil and chemical resistance testing
- Friction coefficient measurement where required
These tests ensure consistent corrosion protection performance.
Applications
High Corrosion Coating is widely used in:
- Automotive fasteners
- Brake components
- Structural brackets
- Springs and clips
- Casting ferrous metal parts
- Magnetic components
- Industrial hardware
It is especially recommended for high-durability components exposed to corrosive environments.
FAQs – High Corrosion Coating
High Corrosion Coating is a zinc-aluminum flake based protective system applied non-electrolytically to provide long-term corrosion resistance for ferrous metal components.
The system can achieve over 1000 hours of Neutral Salt Spray Test when applied with proper thickness and curing conditions.
No. Since it is a non-electrolytic process, there is no hydrogen embrittlement risk.
A minimum coating thickness of 8 microns and coating weight of 240 mg is required for high corrosion performance.
It is widely used in automotive, marine, infrastructure, industrial hardware, and heavy machinery applications.