Electrocoat Primer vs. Traditional Spray Coatings: A New Standard in Aerospace
In the aerospace industry, the integrity and longevity of aircraft components are paramount. Protective coatings play a critical role in safeguarding these parts from corrosion, wear and environmental damage, while also contributing to overall aircraft performance and safety. Traditionally, manual spray-applied primers have been the standard method for coating aircraft parts. However, advances in coating technology have introduced more efficient, sustainable and higher-performing alternatives. Among these innovations, Aerocron electrocoat primer developed by PPG’s Aerospace business stands out as a game-changer.
Aerocron electrocoat primer is a chrome-free*, water-based electrocoat technology specifically developed for aerospace applications. It offers an attractive alternative to manual spray coatings by delivering corrosion protection while helping to improve productivity and reduce waste.
*Chromium is not intentionally added in the formulation of this product. PPG’s “chrome-free” statement is based on our knowledge of the product formulation.
Understanding Manual Spray Coating in Aerospace
Manual spray application has long been a staple in aerospace manufacturing for applying coatings to aircraft parts. The process involves operators manually spraying liquid primer onto components, often requiring multiple passes to achieve adequate coverage. While this method is familiar and widely used, it presents several challenges:
- Inconsistent Coverage: Manual spraying can result in uneven film thickness, runs, drips and sags, especially on complex geometries and recessed areas. This inconsistency can compromise properties such as corrosion protection and paint adhesion.
- Material Waste: Overspray is common, leading to significant paint waste and increased costs.
- Environmental Impact: Higher VOC emissions and paint waste contribute to environmental concerns and regulatory challenges.
- Labor Intensity and Production Time: Manual spraying is labor-intensive and time-consuming, often requiring rework to correct defects.
Given these limitations, aerospace manufacturers are seeking more efficient, safer and more sustainable coating methods.
What is PPG’s Aerocron Electrocoat Primer Technology?
Aerocron electrocoat primer is PPG’s innovative chrome-free* electrocoat solution designed specifically for aerospace substrates. Unlike manual spray application, the electrocoat process uses electrical current to drive deposition of the primer uniformly onto conductive parts.
In the electrocoating process, aircraft components made from aluminum alloys (such as 2024, 2050, 2214, 5083, 6056, 6061, 7075, 7175 and AS7G), titanium or stainless steel are immersed in a tank containing the water-based primer. An electrical charge causes the primer particles to migrate and bond evenly to the part’s surface, including hard-to-reach recessed areas. This results in a uniform, precise film thickness with minimal waste.
Aerocron electrocoat primer is compatible with both chromate and chrome-free* pretreatments and works with industry standard topcoats. Its advanced formulation ensures outstanding corrosion resistance, excellent paint adhesion and durability required for the demanding conditions of flight.
Key Advantages of Using Electrocoat Primer Over Manual Spray Coatings
1. Superior Coating Quality and Coverage
Electrically driven deposition of the electrocoat primer provides uniform coverage on complex shapes and recessed areas that are difficult to coat consistently with manual spray methods. The precise film thickness control minimizes defects such as runs, drips and sags, which are common in spray applications. Additionally, the electrocoat process reduces material waste and ensuring that nearly all primer applied adheres to the part.
2. Sustainability Benefits
The chrome-free* and water-based formulation of PPG’s Aerocron electrocoat primer have a low VOC level, below 150 grams per liter, which helps aerospace manufacturers comply with stringent environmental regulations.
The closed-loop nature of the electrocoating process minimizes waste discharge, and the high transfer efficiency (90-95%) means less primer is wasted. The low fire hazard of the water-based system also enhances workplace safety.
3. Enhanced Productivity and Operational Efficiency
Electrocoat primer application can be highly automated, requiring only one operator to maintain and run the system. This automation reduces labor intensity and the potential for human error inherent in manual spray application. This results in reduced rework rates due to consistent coating quality and further streamlines manufacturing, helping save time and costs.
The process includes a thermal cure cycle that enables immediate handling of fully cured parts, accelerating production throughput. The e-coat process also supports non-uniform line loading, allowing flexible production scheduling and improved efficiency.
4. Weight Savings and Operational Cost Reduction
Aerocron electrocoat primer can contribute to overall aircraft weight reduction, a critical factor in aerospace design. It is lighter weight than traditional chromated spray primers and its more precise application process virtually eliminates excess paint use with traditional spray-applied coating methods. Even small weight savings can translate into fuel efficiency improvements, which may lower operational costs over an aircraft’s lifecycle and reduce environmental impact.
5. Proven Performance and Industry Acceptance
Aerocron electrocoat primer from PPG is SAE/AMS-3144 qualified, demonstrating its reliability and suitability for demanding aerospace environments. Its exceptional corrosion resistance and barrier properties protect aircraft structures from harsh conditions encountered during flight, helping ensure long-lasting finishes and structural integrity.
Risks of Continuing with Manual Spray Coatings
Choosing to maintain manual spray-applied coatings carries several risks:
- Greater material waste and environmental impact due to overspray and inefficient application.
- Inconsistent coating quality leading to higher rework rates, production delays and increased costs.
- Missed opportunities for weight reduction and fuel savings, impacting aircraft operational efficiency.
- Challenges in meeting evolving environmental regulations and sustainability goals.
The PPG Advantage
The Aerocron electrocoat primer technology developed by PPG’s Aerospace business represents a significant advancement in aerospace coatings technology. By replacing manual spray-applied primers with Aerocron electrocoat primers, manufacturers gain corrosion protection, improved paint adhesion and consistent coverage on complex parts. The chrome-free*, water-based formulation helps you meet your sustainability goals, while the automated process helps boost productivity and lower operational costs. The lightweighting properties of Aerocron electrocoat primers contribute to aircraft weight reduction, supporting fuel efficiency and sustainability initiatives critical to the aerospace industry’s future.
Ready to experience the power of PPG’s Aerocron electrocoat primers?
Discover how PPG’s chrome-free* Aerocron electrocoat primer technology boosts aerospace coating over traditional manual spray-applied methods. Contact PPG’s Aerospace business today to learn how Aerocron electrocoat primers can enhance the performance, safety and longevity of your aircraft components.
Our expert team is available to provide technical support, product samples and guidance to help you elevate your aerospace coatings to new heights.
*Chromium is not intentionally added in the formulation of this product. PPG’s “chrome-free” statement is based on our knowledge of the product formulation.