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Need economical coating/plating to pass 1000 hour salt spray test

Q. Hello,
I hope you can help me out. I have high quantity of steel plates and weldments that I need a coating or plating that would pass a 1000 hour salt spray test. The coating or plating needs to be fairly cheap. Looks after plating or coating is not important at all. The other requirement is it has to be blue in color, shade of blue doesn't matter. There are 60000 pieces around 1/2" x 5" x 5" in size. The weldment is 2" x 2" x 1/8" wall steel tubing around 3 feet long. There is also around 60000 of these also. Any advice on what to look for or who can do this would be greatly appreciated. Thanks in advance.

Steve Boyle
Job Shop - Deptford, New Jersey, USA
May 29, 2010

A. Hi, Steve. A good quality epoxy or polyester powder coating after a good pretreatment should be able to go a thousand hours, but you may need more weld preparation than you would prefer, and you may require an electrophoretic primer first because absolutely zero pinholes may prove difficult depending on the parts. Galvanizing sounds like another good answer, with exceptional real-life performance, but salt-spray testing of galvanizing is problematic because its actual corrosion resistance requires the formation of intermediates that won't form in a salt spray test chamber. Unfortunately, what is probably the most protective coating in real life performs poorly in salt spray testing.


Ted Mooney,
Ted Mooney, P.E.
Striving to live Aloha - Pine Beach, New Jersey

A. Hi Steve Boyle,
Better try with Nylon based Powder coating, it is available in blue color.

Kannan Boopathi
- Salem, Tamil Nadu, India

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