Aluminum electrophoresis white process technology introduction
[China Aluminum Network] Since its introduction for metal decoration and corrosion protection, electrophoresis technology has found widespread use across various industries and materials, especially in the automotive sector. Over time, it has evolved rapidly. In the aluminum profile industry, Japan pioneered electrophoresis techniques for aluminum profiles as early as the 1960s, and these methods have since become widely adopted within the aluminum industry. China introduced this technology over 20 years ago, and after more than two decades of development, electrophoretic production lines are now established in every province and autonomous region. Electrophoretic aluminum materials have been extensively used in numerous applications, while white and colored aluminum materials have also seen significant growth. However, currently, white electrophoretic coatings are mainly applied to aluminum materials using anode electrophoretic paints, which are largely imported from abroad. This technology is dominated by foreign companies. After years of research and development, Wuhan Collier Chemical Co., Ltd. has successfully developed a high-performance aqueous polyurethane cathodic electrophoretic resin and obtained a national invention patent. Based on this innovation, they have created a white polyurethane cathodic electrophoretic paint. In Nanhai, Guangdong, a vertical cathode white electrophoresis line was established, and after three months of trial operation, the equipment ran smoothly, the electrophoretic bath remained stable, and it proved suitable for industrial-scale production. Compared to traditional anode white electrophoretic coatings, this new method offers advantages in process efficiency, energy consumption, and environmental protection. The resulting white electrophoretic aluminum material features a smooth film, high hardness, and excellent protective properties. It has gained popularity in applications such as window decoration, aluminum profiles, and furniture materials, and has earned the trust and respect of customers. Below is a detailed discussion and exchange on the white polyurethane electrophoretic paint process and the electrophoresis production line equipment developed by Wuhan Collier Chemical Co., Ltd. Traditional Process (Anode Acrylic White Electrophoretic Coating): 1. Degreasing 2. Flow Washing 3. Alkaline Etching 4. Hot Water Washing 5. Flow Washing 6. Neutralization 7. Flow Washing 8. Flow Washing 9. Oxidation 10. Flow Washing 11. Flow Washing 12. Pure Water Washing 13. Pure Water Washing 14. Anode White Electrophoresis 15. Pure Water Wash (Spray) 16. Pure Water Wash 17. Pure Water Wash 18. Drying New Process (Cathode Polyurethane White Electrophoretic Coating – Example from Wuhan Collier Production Line): 1. Degreasing 2. Flow Washing 3. Flow Washing 4. Pure Water Washing 5. Pure Water Washing 6. Pure Water Washing 7. Cathode Polyurethane White Electrophoresis 8. UF Water Washing (Spray) 9. Pure Water Washing 10. Pure Water Washing 11. Drying Compared to the traditional process, the new method is much simpler in terms of procedure and operation, making it more convenient and efficient. For example, this process is commonly used in the production of aluminum profile door curtain tracks. Main Equipment: 1. Electrophoresis Tank: Made of PVC, equipped with a liquid circulation filtration system, ultrafiltration system, and a cold/heat exchange circulation system. The tank must be designed so that the coated workpiece is 10–20 cm above the bottom, no less than 15 cm from the plate, and submerged 5–10 cm below the surface. The tank's surface flow rate should be around 0.2 m/s, with a circulation rate of 4–6 times per hour. 2. Ultrafiltration Machine: Uses a semi-permeable membrane to separate pigments, polymer resins, organic solvents, and inorganic impurities from the bath solution. Available types include tube, roll, hollow fiber, and plate. Currently, coil and hollow fiber types are most common, with the hollow fiber membrane being KL-Q04 type. The ultrafiltration system has a capacity of 200 L/h. 3. Pure Water Machine: Electrophoresis requires high-quality pure water. A R-1000 reverse osmosis unit is typically selected, producing 1 T/h of purified water. 4. Power Supply: Domestic electrophoretic power supplies are similar to those used globally. They feature soft start/stop, automatic timing, voltage limit, current protection, and over-voltage and short-circuit safeguards. 5. Cooling and Heating Units: Use imported brand inverters and electronic control systems for precise temperature regulation. These units can manage multiple zones and are highly flexible. 6. Racks: Designed according to product requirements, process parameters, and specifications. Degreasing: This step removes oxide layers and oil residues from the aluminum surface. The process uses Wuhan Collier’s K-301 acid degreaser at a concentration of 5–8% for 5–8 minutes at room temperature. Flow Washing 2: Removes residual water and dirt from the workpiece. The pH must be ≥ 5.5, conductivity ≤ 180 μS/cm, and each wash lasts one minute.
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