Detailed e-Coating (electrophoretic-Coating) Process for Heat Exchangers and Radiators

1 - e-Coating Process
2 - e-Coating Process Dip Tanks 1-5
3 - e-Coating Process Dip Tanks 6-10
4 - e-Coating Process Oven Cure
5 - e-Coating Process Top Coat

Outokumpu, the world's largest supplier of copper and brass, reported in its "CuproBraze Technical Manual" the following: "Electrophoretic Coating [e-Coating] is the best technical solution to increase corrosion resistance [for heat exchangers]." (Section 7.2.3 Coatings)

TANK 1 - The CoreKote Process starts with the removal of a weak Oxide layer that has formed in the bare surface. Heated Alkaline cleaning is used to remove the oxide film and any process lubricant residues

TANK 2 & 3 - A neutral PH rinse is used to remove the oxide film and process lubricant residues

TANK 4 - A full immersion process then deposits the Zirconium * Oxide layer on the surface of the material. A conversion layer forms on the surface enhancing improved fin edge build and adhesion.
* Zirconium corrosion resistance has been tested as a stand alone material, showing improved protection

Organic Zirconium Pretreatment Designed For High Performance On All Substrates.
Extremely Uniform Coatings Promote Uniform E-coat Applications
Technology Proven In HVAC, Appliance, Construction, And Agriculture Industries.
Zirconium Oxide Material is a High Strength Particulate Matter
Formation of a Barrier Layer - Restricting Ion, Water and Oxygen Access to the Substrate
Chemical and Mechanical Stabilization of the Native Oxide Film
Environmentally Friendly, No Heavy Metals, Ambient Application

TANK 5 - Rinse

TANK 6 & 7 - After pretreatment, coils pass thru multiple rinse tanks to ensure a neutral ph surface.

TANK 8 - E-COATING Full Immersion With our patented technology, film build is controlled to +- .0002. Anode control ensures no bridging and 100% coated to the center.

TANK 9 & 10 - Post rinse before curing ensures no loose material is left on the surface, contributing to an even film build.

OVEN CURE - The next stage is oven cure. Axalta E-coat material is a lower temperature cure (355F) then other E-coats on the market.

TOP COAT - Final stage is the Spray Top Coat. This provides an additional protective layer and attractive finish.

Why Se-Cliff over other e-Coaters?

Other e-Coat applicators e-Coat simple, geometrical parts/shapes. Their electronics that drive the paint on such e-Coating systems are not designed to drive the coating into complex geometrical shapes—very few e-Coaters worldwide have the necessary, sophisticated electronic/anodic systems. In the past, we have seen several problems when "simple geometry," e-Coating applicators attempt to e-Coat heat exchangers (which is, by the way, 98+% of all the parts we e-Coat. We have now begun e-Coating fan shrouds and other associated steel parts to meet customer specifications.)

Here are the very serious problems associated with applicators that attempt to e-Coat heat exchangers when their systems are designed to e-Coat simple, geometrical parts:

Voids within the interior of the fin nest as a result of too little current driving the paint.
Clogging in the interior and face of the fin nest as a result of overcompensating and using too much current to drive the paint.
A phenomenon occurs when the e-Coat paint formula cannot handle the necessary current for the complex geometry. Hydrogen is stripped from the paint, creating bubbling on the surface of the part.