Autophoretic, also known as autodepostion or A-coat, is a waterborne process

which depends on chemical reactions to achieve deposition. This process has

been in commercial use since 1975. Since then, Autophoretic has grown and
matured. Since its inception, this unique process has been employed to coat
billions of square feet of surface. Presently, there are numerous installations in
operation, both captive and job-shop, coating a variety of fabricated steel parts
for the automotive and general industry markets.

An Autophoretic bath consists of a mildly acidic latex emulsion polymer, DI water,

and other proprietary ingredients. The bath solids are normally between 3% and
5% by weight. The bath viscosity is close to that of water with little or no organic
solvents in the coating bath. Another characteristic of the Autophoretic coating
process is that is quite simple in comparison to other coating systems. The mildly
acid bath liberates a small amount of iron from the steel parts being immersed,
causing an immediate surface reaction that releases iron ions. These ions
interact with the latex in solution causing coating deposition on the surface of the
steel parts. The newly deposited organic film is adherent yet quite porous. This
allows the chemical activators to diffuse rapidly in the film and etch the surface of
the metal. The continuous formation of coating provides a film with a high degree
of surface protection and corrosion resistance.

The coating thickness of the autodeposited film is time and temperature related.
The film thickness continues to grow as long as ionic species are being produced
at the coating/metal interface. Initially, the deposition process is quite rapid, but
slows down as the film increases in thickness. Typically, film thickness is
controlled from 0.6 to 1.0 mil.

A unique feature of the Autophoretic process is the formation of a very uniform

film over the entire surface of the workpiece, even in difficult-to-reach areas. This
allows the coating dispersion to flow into and around the most complex shapes.
Unlike coating processes that require a charge to deposit the coating (i.e., where
electrical energy is required to "throw" the coating into recessed areas)
Autophoretic will coat tubular, assembled, or intricate-design areas uniformly.
Autophoretic coating film thickness is controlled by diffusion of reactants in the
bath and through the coating already formed on the surface of the substrate. This
diffusion control leads to a uniform coating thickness on complex shapes and in
recessed areas.

The film formed by the Autophoretic process is most unique for a latex vehicle.
Latex films form by coalescence. However, the degree to which the film forms in
the Autophoretic process via the coalescing action, is the basis for its
uniqueness. Parts coated via Autophoretic can be water rinsed immediately after
leaving the bath with very little material loss. 

On leaving the bath, the coating consists of two layers; one is a very cohesive
reacted layer; while the other is composed of undeposited excess polymer and
activator from the bath. The chemical reaction continues in the second layer,
which results in film deposition and increased film thickness instead of solids loss
to dragout. This unusual feature strongly limits carryover of coating chemicals
into the rinse tanks and greatly reduces the demand for waste treatment.

It should also be mentioned that the Autophoretic process does not require a
chemical conversion coating (such as zinc or iron phosphate) stage or, in the
case of an Autophoretic process using Autophoretic 800 Series coating chemical,
even a heavy metal final rinse stage. The elimination of these stages leads to
considerable savings in required floor space, energy, and operating costs, as
well as the total elimination of toxic metals from the process. Considerably lower
temperatures are required to cure the autodeposited parts. These are just some
of the many advantages of using the Autophoretic process.
 Only metal substrstes will autodeposit in the coating solution

Metal ions from the substrate complex with the pigment latex and then deposit

As autodeposition continues, coating becomes uniform as the reaction stops with

thickness