Corrosion presents a significant challenge in metal applications, leading to structural degradation, aesthetic deterioration, and increased maintenance costs. High-performance powder coating is an advanced protective solution that enhances corrosion resistance by providing a uniform, durable barrier against environmental conditions and external elements.
While there’s no technical designation for “high-peformance” powder coating versus conventional powder coating, there are a multitude of ways in which powder formulations can be engineered to provide better durability and enhanced corrosion resistance.
Rest assured that Winona always chooses an optimal powder formulation to meet your requirements in corrosion protection as well as all other performance specifications.
The Anatomy of a Powder Coating Formulation
There are numerous powder coating types – most commonly acrylic, epoxy, fluoropolymers, and polyester. There are also slight variations between different formulations, with special additives and agents mixed in to enhance the performance and/or protective properties.
- Resin – Most commonly epoxy or polyester.
- Curing Agent – Facilitates the curing process to create a durable, fully formed protective layer.
- Tints – Allow us to customize the color of the coating.
- Additives – Powder coating additives come in many forms and functions, from creating a glossy finish or adding textures to improving the overall hardness.
- Extenders or Fillers – Likewise, there are many different powder coating extenders and fillers, typically used to provide enhanced durability.
As you can see, it’s primarily the choice of additives, extenders, and fillers that separate high-performance powder coatings from more conventional formulations.
A Brief Primer on Metal Corrosion
Understanding the protective properties of high-performance powder coatings requires a bit of knowledge on what corrosion is, and how it develops. Basically, corrosion occurs whenever metals chemically react with water, oxygen, chemicals, or other contaminants – any external substance that is chemically reactive with elements in the metal alloy. As elements in the external substance react with elements on the metal surface, corrosion results in the form of rust, oxidation, or other types of material breakdown.
How Powder Coating Prevents Rust, Oxidation, and Chemical Corrosion
High-performance powder coatings function as a shield that mitigates the formation of corrosion via three primary modes of protection:
- Surface Barrier Protection – A continuous, non-porous film prevents exposure to corrosive agents, such as the ingress of water, moisture, and chemicals.
- Chemical Resistance – Advanced resin formulations are resistant to chemicals, moisture, and UV radiation.
- Electrochemical Protection – Special corrosion inhibitors further reduce metal-ion dissolution (i.e. corrosion), preventing rust and other forms of oxidation.
In other words, the powder coating layer acts as a physical barrier, sealing the substrate from moisture, oxygen, and other corrosive agents that would otherwise cause corrosion. Compared to wet paint, powder coatings cure into a denser, more uniform film that eliminates virtually all gaps and pores, significantly reducing the risk of corrosive infiltration. Moreover, the inherent durability of powder coatings ensures long-lasting resistance to environmental factors such as humidity, salt spray, and prolonged chemical exposure.
Additionally, as mentioned above, high-performancer powder coatings are formulated with corrosion inhibitors and advanced resins that enhance their resistance to harsh conditions. Epoxy-based powders offer exceptional adhesion and chemical resistance, making them ideal for industrial and marine environments, while polyurethane and hybrid coatings provide superior UV stability and mechanical durability for exterior applications. Zinc-rich primers further bolster corrosion resistance by offering sacrificial cathodic protection, reducing the risk of substrate oxidation and extending the lifespan of metal components.
Quality American Powder Coating Services for Industrial Applications
Founded in 1974, Winona Powder Coating has grown into one of the Midwest’s premier powder coating service providers for the industrial sector and beyond. With two locations based out of Etna Green and Elkhart, Indiana, our company has served the commercial metal finishing industry for more than 50 years.