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Zinc flake coatings

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Zinc flake coatings

Zinc flake coatings consist of lamellar metal particles in an inorganic binder matrix, which are applied non-electrolytically.  They are applied to the component like a wet paint using various processes and cross-linked to a solid film by heat treatment at typically 180 - 240°C (solvent-dilutable) or 290 - 310°C (water-dilutable).

In addition to binders and solvents, the liquid coating material contains a very high proportion of corrosion protection pigments.  After application and during heating of the components, these zinc and aluminium (or alloy) plates align in many layers.  As the solvents evaporate during the heating process, many layers of these lamellas are formed which lie close to each other and are each coated with a binder.  This cross-links at higher temperatures and thus produces a coating that adheres to the substrate material

An additionally applied topcoat favours further properties of the zinc flake system.  The sealing is often produced in the same application process and at similar temperatures as the basecoat. The process is aimed at the components to be coated and the requirements for the resulting coating.

The following control variables are relevant for the structure and quality of the coating in an adapted system technology:

  • Surface quality of the components to be coated
  • Viscosity and solids content of the coating material
  • Application parameters (depending on process)
  • Temperature and time of heat treatment for crosslinking/curing
  • Racks / goods movement adapted to the component geometry

Mainly metallic components made of ferrous materials are coated in industrial plants.  Zinc flake systems are typically used in the automotive industry, but also in commercial vehicles, wind turbines, agricultural machines, buildings and especially on springs, clamps, screws and other connecting elements.


Fig: Schematic representation of cathodic corrosion protection

Misc pages

Curing in process
Conveyor belt oven (continuous oven)
Tray oven (continuos oven)
Chain conveyor oven
Chamber oven
Drying process
Cooling (after annealing)
Exhaust air treatment
KTL breakdown voltage
Condensed water test according to DIN EN ISO 6270-2
Sacrificial anode
Local element
Surface protection
Hot-dip galvanising
Flame spraying
Galvanic coating
Conversion layer
Dry-film coat thickness
Fastening properties
Gloss level
Artificial weathering test
Test procedures
Surface properties
Chemical resistance
Mechanical resistance
Natural weathering test
Physical properties
Passiveness, passive state
Protection, galvanic
Protection, temporary
Chromate Coating
Passivation coating
Rack coating
Bulk process
Partial production lot
Drum coating
Erichsen ball recess
Coating thickness, total
Coating thickness, local
Coating thickness, reference
Coating weight
Dry to the touch
Reference surface
Spray coating
Electroplated coating
Specific surface
Passive corrosion protection
Inorganic protective coatings
Organic protective coatings
Active corrosion protection
Forms of corrosion
Types of corrosion
Surface corrosion
Shallow pitting corrosion
Pitting corrosion
Contact corrosion
Bimetallic corrosion
Stress corrosion cracking
Hydrogen induced cracking
ISO 9001
Electro-dip painting (ETL)
Electrostatic powder spraying (EPS)
ISO 14001
Trueness of gauge
Coefficient of friction
Setting behaviour
Fastening and assembly
Kesternich test
Material effectiveness
Environmental management
Quality management
Magnetic induction measurement
Scaling protection
Powder coating
Coil coating
X-ray fluorescence analysis
Beta backscatter method
Mandrel bend test
Eddy current method (phase sensitive)
Eddy current method (amplitude sensitive)
Corrosion College
Powder sintering process
Zinc flake coatings
Dip coating process
Stone impact test
Process stages of KTL-seperation
Corrosion testing atmospheres conducive corrosion
Coat thickness and coat thickness measurement
Adhesion test according to DIN EN ISO 10683
Cross-cut test for adhesion
Thread tolerance
Pressure water jetting test
Fertiliser resistance
Anodic dip coating (ADC)
Cathodic dip coating (CDC)

Technical terms can not always be avoided. As corrosion experts, we not only want to give you comprehensive advice, we are also interested in making you a corrosion expert yourself.

The variety around the topic of corrosion and corrosion protection is also in our glossary at home: explanations from A as in Adhesion to T as in Thread tolerance. Have fun clicking through!