Powder Coating of Aircraft Parts

Powder coating is a dry finishing process used to provide durable, corrosion-resistant, and aesthetically pleasing coatings for aircraft components. Unlike traditional liquid coatings, powder coating involves electrostatically applying a dry powder to a part and curing it under heat to form a protective layer.

Powder coatings are commonly used on landing gear, structural components, fasteners, brackets, and aircraft interior parts to ensure long-lasting performance under extreme conditions.

How Powder Coating Works

1. Surface Preparation Parts are cleaned, degreased, and sometimes blasted to remove contaminants. A pre-treatment (such as chromate or phosphate coating) may be applied for better adhesion.
2. Electrostatic Powder Application A fine powder (polyester, epoxy, or hybrid blend) is applied using an electrostatic spray gun. The charged particles stick to the metal surface, creating an even coating.
3. Curing Process The coated part is heated in an oven (typically 300–400°F / 150–200°C). The heat melts and fuses the powder into a smooth, uniform, and durable finish.
4. Cooling & Inspection The part is cooled to harden the coating, and it is then inspected for thickness, adhesion, and uniformity.

Benefits of Powder Coating for Aircraft Parts

✅ Exceptional Corrosion Resistance – Protects against oxidation, salt, moisture, and chemicals. ✅ Superior Durability – Resists scratches, chips, impact damage, and wear. ✅ Chemical & Fuel Resistance – Ideal for aircraft parts exposed to hydraulic fluids, fuel, and lubricants. ✅ Eco-Friendly (No VOCs) – Unlike liquid paints, powder coating contains no solvents or harmful volatile organic compounds (VOCs). ✅ Uniform & Aesthetic Finish – Provides smooth, even coverage without drips, runs, or uneven areas. ✅ High Heat & UV Resistance – Withstands harsh environmental conditions and extreme temperatures.

Aerospace Applications of Powder Coating

✔ Landing Gear & Struts – Protects against abrasion and exposure to de-icing chemicals. ✔ Interior Components – Used on seats, brackets, and overhead bins for durability and aesthetics. ✔ Fasteners & Hardware – Ensures long-term corrosion protection. ✔ Aircraft Frames & Structural Parts – Reduces maintenance by preventing rust and wear. ✔ Engine & Exhaust Components – Special heat-resistant powders can be used for thermal protection.

Comparison: Powder Coating vs. Other Aircraft Coatings