Analysis of the Effect of Powder Coating Methods on Corrosion and Abrasion Resistance in Aluminum and Light Steel

Abstract

Powder coating is a widely used method for protecting metals from corrosion and enhancing their resistance to environmental conditions. This study aimed to evaluate the effect of epoxy-based powder coating on aluminum and light steel in terms of corrosion resistance, weather resistance, and maintenance efficiency. Aluminum samples with thicknesses of 15, 18, and 22 mm and light steel samples with thicknesses of 0,4, 0,7, and 2,2 mm were coated using an electrostatic spray gun. Variations were also applied based on coating thickness, namely aluminum 0,26, 0,28, and 0,31 mm, and light steel 0,1, 0,3, and 0,5 mm. Corrosion rate testing was conducted by immersing the samples in a saltwater solution for 216 hours, and surface degradation was evaluated using a scale from 1 to 5, where 1 indicates the lowest corrosion. The results showed that aluminum with a thickness of 22 mm and a coating of 0,31 mm exhibited the best corrosion resistance at level 1 due to its naturally higher oxidation resistance and good coating adhesion. Light steel also showed improved resistance, but its corrosion level was higher. This study confirms that powder coating is an effective and economical method to enhance the durability of aluminum and light steel, particularly at optimal material and coating thicknesses.