Powder Coating - Ceramic Coating - Process

They Call It Powdercoating, But What Is It?
Powdercoating media is a thermosetting powder substance that is made up of polyester epoxy and acrylic resin, combined with various cross-linking compounds. What all that fancy terminology means is a durable, show-ready coating that protects all types of metals. The powder particles are so fine they resemble talcum powder. The spray application uses a fluidized bed as a feed hopper to hold the powder and fluidize it so that it can be pumped to the tip of the spray gun using compressed air to transport it from the feed hopper. The spray gun is designed to create an electrostatic charge known as corona charging, or by frictional contact with the inside of the gun barrel, called tribo charging. Positively charged particles are then attracted to the negative ground metallic parts causing static cling. Grounded powdercoat parts are then put into a baking oven to heat the powder particles causing them to transform into liquid form and then cure.

Ceramic coating creates a thermal heat barrier between the metal surface and heat source. In this story we will be ceramic coating headers and exhaust system. By creating a thermal barrier of the header, the heat of the burnt gasses are kept within the header that will accelerate the exhaust gas velocity decreasing backpressure and reducing fuel consumption due to reversion. Ceramic coating will help contain the heat inside the header reducing its heat from being radiated to other engine components under the hood like the alternator, starter, ignition coils, wires, carburetor, fuel rails, injectors, battery and radiator. Not to mention transferring heat into the driver compartment. Ceramic coating helps extend the header's life fighting against corrosion. Specialized uses aluminum oxide to media blast the parts. It is suggested to pre heat the parts in an oven to 400-500 degrees Farenheit that will sweat out contaminants from the pores of the material, especially cast aluminum or iron. After the parts are cooled to ambient temperature, the ceramic coating can be applied. Ceramic coating is a liquid that is applied through a detail spray gun. Ceramic is introduced to the part with a fog coat then followed with a couple of primary coats. The ceramic-coated part is then baked in an oven. The degrees and cycle time depends on the size and thickness of the part. It is then ambient cooled.

Checkout the powdercoating and ceramic coating processes as we followed the professionals at Specialized Coatings in Huntington Beach, California.

1. The first step of powdercoating is to thoroughly clean the metallic parts. The front suspension parts were pre-baked in the oven at 500º F. This would sweat out any contaminant, such as oil or grease. The parts are then allowed to ambient cool before being placed in the media blasting cabinet. Inside the blasting cabinet the parts were blasted using aluminum oxide 120 grit media to remove any dirt, oil, grease, rust, or any other contaminates. This photo of the McGaughy's spindles shows the before media blasted spindle and the after media blasted spindle. Any contaminant on the surface will cause delamination or blistering of the powdercoating from the part's surface.
1. The first step of powdercoating is to thoroughly clean the metallic parts. The front su
2. Wherever powdercoat is not wanted, the parts must be masked using high temp (400º) polyester tape with a silicone adhesive backing.
2. Wherever powdercoat is not wanted, the parts must be masked using high temp (400º) poly

3. After the parts were properly cleaned using the correct abrasive media, they were then placed in the oven where they were pre-heated then hung on the grounded coating rack. By pre heating the parts they will attract more powder to cling to their grounded surfaces.
3. After the parts were properly cleaned using the correct abrasive media, they were then
4. After pouring the Spraylat (super wet black) powder into the Nordson feed hopper, Martin Quezada fired up the electrostatic corona Nordson Versa spray gun, then set the air pressure regulator to 10 psi and squeezed the trigger covering the front suspension parts uniformly with electrostatic charged powder.
4. After pouring the Spraylat (super wet black) powder into the Nordson feed hopper, Marti
5. The front suspension components were thoroughly covered with gloss black powder that statically clung to every grounded metallic parts surface. Martin then rolled the hanging parts into the baking oven. After the oven doors were closed, Martin set the pre-heated oven to 390º F for one hour baking and curing time.
5. The front suspension components were thoroughly covered with gloss black powder that st

6. The front suspension components were thoroughly covered with gloss black powder that statically clung to every grounded metallic parts surface. Martin then rolled the hanging parts into the baking oven. After the oven doors were closed, Martin set the pre-heated oven to 390º F for one hour baking and curing time.
6. The front suspension components were thoroughly covered with gloss black powder that st
7. The front suspension components were thoroughly covered with gloss black powder that statically clung to every grounded metallic parts surface. Martin then rolled the hanging parts into the baking oven. After the oven doors were closed, Martin set the pre-heated oven to 390º F for one hour baking and curing time.
7. The front suspension components were thoroughly covered with gloss black powder that st
8. Following the slow baking time of one hour and 40 minutes the front suspension parts were then rolled out of the oven and set aside to ambient cool.
8. Following the slow baking time of one hour and 40 minutes the front suspension parts we

9. Because the powder was baked on, it allowed the powder to fluidize and flow into a super high gloss durable coating.
9. Because the powder was baked on, it allowed the powder to fluidize and flow into a supe
10. Ceramic coating is a way to thermally protect and dissipate heat from exhaust manifolds and headers. Plus, it creates a uniform coating that improves the appearance of each part. Ceramic coating is also also used to create a heat barrier between dissimilar metals of internal engine components. Ceramic is available in Chromex, satin black, tungsten, titanium and gold, custom colors upon request.
10. Ceramic coating is a way to thermally protect and dissipate heat from exhaust manifold
11. The American Racing Headers long-tube headers were pre-baked at 400º F to sweat out any contaminants, then allowed to ambient cool before being placed into the blasting cabinet.
11. The American Racing Headers long-tube headers were pre-baked at 400º F to sweat out an