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Aluminum Powder Coating – The Complete Guide

Aluminum Powder Coating – The Complete Guide

If you are looking for any information on aluminum powder coating, you will find the information right here.

Whether want to learn about the step-by-step process, benefits, or short comings of powder coating aluminum, you will find the information right here.

Keep reading to learn more.

Step-by-step Powder Coating Process

Aluminum powder coating is a step-by-step process which involve many stages. Remember, each stage plays an integral role in the entire powder coating aluminum.

Let’s look at some critical stages.


Step 1:- Pre-treating Aluminum for Powder Coating

First you should remove all impurities in the aluminum sheet metal. These impurities may include dust, grime and grease takes place.

Pretreatment occurs in several stages purposefully to curb the negative impact of impurities on the powder’s adhesion.

The stages involve; – power washing, solvent cleaning, alkaline cleaning and hand cleaning.


Step 2:-Preparing Aluminum Surface

Surface preparation occurs through the application of treatment by phosphate or the blasting method. The aim is to clear away any trace of aluminum oxide and ensure proper roughening to enhance powder adhesion.

Below are simple ways to prepare aluminum surface using different techniques:

Powder Coated Aluminum Parts
Powder Coated Aluminum Parts

Phosphate Treatment

Phosphate treatment occurs in different ways such as through, spraying of the surface, complete immersion and using a smooth brush application.

The process enables the reaction of Aluminum with the phosphate solution, forming a phosphate coating that is crystalline in nature.

Sweep Blasting

This involves blasting the abrasive media on the metal surface through the exertion of pressure on air, ensuring a rough surface.

Step 3:-Applying Powder on Aluminum Surface

An electrostatic spray gun generates the electrostatic charge difference resulting to the build-up and sticking of powder particles on Aluminum surface.

Step 4:- Curing Powder Coating Aluminum Surface

The curing process begins immediately Aluminum obtains a standard coating thickness.

The heating process occurs in large ovens and lasts for different periods resulting in a molten coating that is purely uniform.

Step 5:-Cooling Powder Coated Aluminum Surface

After the completion of the baking process, aluminum parts are left to cool off and form different coatings.

Aluminum Power Coating Procedure Guideline
Aluminum Power Coating Procedure Guideline

Advantages of Aluminum Powder Coating Process

Powder coating aluminum surface has proved to an effective way to apply protective and decorative coating. This is because it has many benefits such as:

  • It improves the aesthetic value of Aluminum through enabling incorporation of various designs and surface finishes.
  • Powder coating excludes the involvement of organic compounds with volatile nature, thus favorable during the curing process.
  • The overspray resulting from powder coating is recyclable thus preventing wastes.
  • We obtain strong and tough layers formation from powder coating.
  • Leads to an increase in corrosion resistance.
  • There is a short term curing period for powder coating.
  • Results to high wear resistance.
  • It is an environmentally friendly process due to lack of application of solvents.

Powder Coating Aluminum Problems

Even thou powder coated aluminum sheets have many benefits, there are certain factors you must consider when choosing this technology.

  • Powder coating requires a high capital intensive, thus a costly process.
  • Results to inconsistency in color match.
  • The appearance of filiform on aluminum joints.
  • An effect of orange peeling
  • There are instances of adhesion failures.
  • Chalking effect.

Types Of Powder Coating for Aluminum Sheets

Broadly, you can choose any of thee powder options:

i. Thermoplastic

ii. Thermoset

iii. UV Curable Coatings

Powder Coating Aluminum Vs. Painting Aluminum

If you handling any aluminum sheet metal fabrication project, probably you are wondering whether to choose powder coating or painting.

Let’s make this simple and easy for you:

Powder Coating

Paint Coating

Chances of inconsistency in color matchGreat accuracy in mixing and matching color finishes.
Powder coats are highly flexible with great degrees of strength.Paint coats are not flexible, they easily break.
Powder polymers lack volatile organic compounds which are harmful to the environment.Contain volatile organic compounds causing harmful emissions to the atmosphere.
It is cost effective.An expensive option
The overspray is recyclable.It is not recyclable.
A time saving process.Time consuming process.
Paint Coating Cycle
Paint Coating Cycle

FAQs on Powder Coating Aluminum

Can Powder Coated Aluminum Rust?

No. Powder coating of aluminum enables it to form a protective barrier that prevents it from corrosion.

Which Factors Lead to Failing of Aluminum Powder Coatings?

  • Due to poor and improper application of the powder coat on aluminum.
  • Insufficiency in the pretreatment methods on aluminum.


Powder coating is the ultimate and sustainable choice when seeking on a most reliable finishing option for aluminum. It contains a vast of advantages ranging from financial, mechanical to environmental.

More Resources:

Aluminum Sandblasting – Source: KDMFAB

Aluminum Polishing – Source: KDMFAB

Powder Coating Aluminum – Source: Fine Metal Working

Aluminum Fabrication – Source: KDMFAB

Aluminum Powder Coating – Source: Gabrian

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