I've been hearing a lot about powder coating recently since I've been talking about painting some of my parts for my truck. I'm just curious as to how the process is done and why it is better than just painting (besides the fact that the paint will chip off).

I'm actually doing some work for a powdercoater right now so I know a bit about it.

Powdercoating is applied as a powder through electrostatic attraction. The work piece has a ground clamp on it (so to speak) and the powder coming out of the gun is charged so that its attracted to the work piece. Powder basicallly has the consistency of flour, so its kind of gently blown on (I think they only use like 1-2 psi of air to do it). Then the powder is baked on. Depending on the powder it may be baked at 275 degrees for 35 minutes or 400 for 10, theres a million different ways to cure most powders. The powder basically melts in to a gel and when it cools, it forms a very smooth coating over the part.

Depending on the type of powder you can have various resistances to scratching, chemicals, etc. The downside to powder is that once it starts chipping, its done for. My rockers are powdered steel, and they're all bubbling up to the point where i'm just going to paint them with enamel paint. My rear bumper is powdered too, but it was done with a different sort of powder and has virtually no scratches even after being drug through rocks, rolled on, and smashed in to stuff. Its all in the chemistry.

Personally, I paint most of my stuff. Its easy to touch up a part thats scratched, you just break out a spray-bomb or brush and touch it up. Powder, once it starts lifting off the surface, its pretty much done for. I will say that for exposed stuff though, powder can look gorgeous because of its smooth surface, almost 'plastic-like'

I have to stop in to see this guy on Monday, so if you have any real specific questons I can ask him then

yes that is how you do it, my father used to be a big supplier for the powder paint used in powder coating. Its is intresting how glossy it comes out from a dul, powder consitancy, my tow hooks are power coated!

Is there any kind of additive that would increase its resistance to chippage?

Is there any kind of additive that would increase its resistance to chippage?
If it's done properly, nothing else is needed.

The powder is pulverized plastic. There are many different qualities in different plastics. Some are heat resistant, impact resistant and chemical resistant. Some have serveral of these qualities at different levels of resistance. When the powder is baked, it is essentially melting, creating a film around the material and hardens when cooled.
When you have P/Cing done ask about the qualities your looking for.

Another major issue between different polymer based powder coatings is their UV resistance.

Just like any other kind of paint, color effects price, as does base type. Also like any other paint, preparation is key. If you have powder "lifting and flaking" then I would bet it wasn't prepped correctly. I've had millions of dollars worth of equipment powder coated and every once in while, I'd get a frame or something that shed it's paint on the drive over. It happens, but shouldn't. That's why you use somebody that knows what they're doing.

Yeah, the rockers I had done were a quick and dirty job when my friend was first learning to powder stuff.....2 yrs. later and the bumper has held up to everything i've thrown at it. DEFINATELY find someone who's been doing it for a while. Just as a 'for what its worth' the powders on my bumper are a Morton zinc rich primer and a TCI color called 'super durable cat black'.