Atotech’s Zinc Flake Coating

Zinc Flake Coating: A Deep Dive into Atotech’s Innovative Solutions

Introduction

Corrosion protection is a critical consideration for industries like automotive, construction, and aerospace, where components are exposed to harsh environmental conditions. In review of the various methods of corrosion protection, zinc flake coating has emerged as a highly efficient solution, offering superior corrosion resistance without the need for electroplating. Leading the way in this field is Atotech, a global leader in surface finishing technology, with a portfolio of zinc flake coatings designed to meet the rigorous demands of modern industries.

This blog post explores the benefits, applications, and specific advantages of Atotech’s zinc flake coating systems, and how they stand out in the corrosion protection market.

What is Zinc Flake Coating?

Zinc flake coating is a non-electrolytic process applied to steel, aluminium, and other metals to prevent corrosion. Unlike traditional methods such as galvanizing or electroplating, zinc flake coatings form a thin, highly durable film of zinc and aluminium flakes that act as a barrier between the base metal and the environment. This barrier prevents oxidation, which causes corrosion, and provides protection against extreme weather, chemicals, and wear.

Key Features of Zinc Flake Coating:

Non-electrolytic: No need for an electric current, which eliminates the risk of hydrogen embrittlement, a common issue in high-strength steels.

Thin Layer: The coating is applied in very thin layers (typically 5 to 25 microns) whilst still providing excellent protection.

Sacrificial Protection: The zinc flakes corrode preferentially, sacrificing themselves to protect the base metal, ensuring a long-lasting defence.

Why Zinc Flake Coating?

Corrosion Resistance: Zinc flake coatings provide up to 1,000 hours of corrosion resistance in salt spray tests, making them ideal for use in highly corrosive environments such as marine or industrial settings.

High Performance at Low Thickness: Compared to galvanization or other coating techniques, zinc flake coatings deliver outstanding protection in a thinner layer. This means components retain their original dimensions and mechanical properties without adding significant weight or bulk.

No Hydrogen Embrittlement: Since the coating process is non-electrolytic, there is no risk of hydrogen embrittlement, which can weaken metals like high-strength steels.

Eco-friendly: Modern zinc flake coatings, especially those developed by companies like Atotech, are often chromium-free, making them safer for both workers and the environment.

Atotech: Innovating Zinc Flake Coating Solutions

Atotech is recognized globally for its cutting-edge surface finishing technologies. With an extensive portfolio, they offer advanced zinc flake coating solutions that meet various industry standards, including automotive and heavy machinery. Some of impressive products in Atotech’s zinc flake coating range include:

Zintek® 200: A highly durable, environmentally friendly zinc flake coating designed for superior corrosion resistance. Zintek® 200 meets the highest industry standards and is widely used in automotive parts, fasteners, and building components. Its chrome-free formulation makes it a sustainable choice for companies looking to minimize their environmental impact.

Zintek® ONE: A one-layer zinc flake coating solution designed for high-performance and cost efficiency. Zintek® ONE is easy to apply and provides exceptional corrosion resistance with fewer processing steps, making it ideal for mass production of fasteners and small parts.

Top-Coats & Sealers: Atotech’s range of top-coats and sealers are designed to enhance the base zinc flake coating’s performance by improving resistance to chemicals, wear, and friction. The company’s proprietary top-coats also offer customization options such as colour and gloss levels, which are essential for industries like automotive, where both performance and aesthetics matter.

Applications of Atotech’s Zinc Flake Coatings

Automotive Industry: Fasteners, clips, and connectors in cars are exposed to various elements like rain, salt, and road debris. Atotech’s zinc flake coatings protect these small but essential parts, ensuring they maintain their strength and functionality over time.

Construction & Infrastructure: Bridges, towers, and other structural components made of steel require long-lasting corrosion protection. Zinc flake coatings provide an efficient solution, extending the lifespan of critical infrastructure components.

Aerospace & Defense: In aerospace and military applications, where weight and corrosion resistance are key concerns, zinc flake coatings offer a thin, lightweight protective layer that doesn’t compromise performance.

Heavy Machinery: In industries such as mining, agriculture, and marine, heavy machinery parts are subjected to abrasive environments. Zinc flake coatings protect components from rust and wear, reducing maintenance costs and downtime.

Advantages of Atotech’s Zinc Flake Coating Systems

Advanced Chemistry: Atotech’s zinc flake coatings use innovative formulations that provide superior adhesion, flexibility, and corrosion resistance compared to traditional coatings.

Environmental Compliance: With a focus on sustainability, Atotech’s coatings are free of hexavalent chromium, meeting global environmental regulations while still delivering top-tier performance.

Customisable Solutions: Atotech works closely with clients to provide tailored zinc flake coating systems that meet specific industry requirements, from corrosion protection levels to aesthetic finish requirements.

Conclusion

Zinc flake coating has become a preferred method for corrosion protection, especially in industries where durability and environmental compliance are paramount. Atotech’s innovative zinc flake coatings stand out due to their superior performance, eco-friendly formulations, and versatile applications.

With products like Zintek® 200 and Zintek® ONE, Atotech continues to set the standard for surface finishing technology, offering reliable and sustainable solutions for industries that rely on high-performance coatings.

By choosing Atotech, companies can ensure long-lasting protection for their components, while also committing to environmentally responsible practices.