In the automotive industry, one rule is clear: the final quality of a product depends on the precision of every manufacturing step. The connection between two key processes – robotic welding and cathodic electrocoating (E-coat/KTL) – is a perfect example of how the continuity of technologies influences corrosion resistance and the overall durability of individual components.
From a precise weld to perfect protection
Why is the link between robotic welding and E-coating so important? In mechanical engineering, the two processes typically follow one another. Once the part is welded, it is ideal to apply the surface treatment as soon as possible – within a matter of days. This is not only to protect the material against oxidation and corrosion, but also to maintain proper technological sequencing.
This is precisely where it becomes clear how beneficial it is to integrate both processes already during the design and development of the component. Weld design significantly affects how the assembly behaves in immersion baths during surface pretreatment and during the E-coating process itself. A jointly defined technological procedure helps eliminate unwanted effects and defects throughout the electrocoating process.
Robotic welding ensures perfect weld quality
Automated robotic welding provides stable weld quality across the entire production series – both in terms of dimensions, placement, and execution. The result is a dimensionally stable weldment, which is highly desirable today. This minimises the occurrence of defects such as capillaries, cracks, or silicates that could negatively affect the adhesion of the E-coat layer. A flawless weld is therefore the foundation for uniform coverage and long-term durability.
Immersion E-coating reaches even hard-to-access areas
At Automotive Painting Partners (APP), both plants use immersion E-coating – one of the most reliable corrosion protection methods. This technology excels where others struggle: it provides uniform coating even in very hard-to-reach areas and internal sections of components. With nearly 100% surface coverage, the resulting protection is reliable even for complex constructions. Although it is a more costly method, its effectiveness and versatility offer long-term cost savings.
Individual approach and tailor-made E-coating
Even with a highly reliable method like immersion E-coating, certain limitations arise from the behaviour of the electrostatic field. At Automotive Painting Partners, we therefore discuss all requirements with the customer already during the inquiry phase. We propose suitable technical solutions, such as additional technological openings that ensure optimal bath flow. We can prepare a tailor-made E-coating program for each product that reflects the technical specifics of the component and the customer’s needs.
Two technologies, one goal – a perfect surface
Combining robotic welding and E-coating is not just a logical step – it is a strategic decision that significantly affects product quality, durability, and overall cost efficiency. At APP, we know that the path to flawless quality begins with a flawless weld. That is why we approach every project individually and with great attention to precision.
We combine robotic welding and E-coating. The result is highly reliable corrosion protection that meets even the most demanding automotive standards. Get in touch with us.
