**1. Introduction**
The working environment of satellite receiving antennas is typically harsh, exposing them to various environmental factors such as humidity, temperature fluctuations, and corrosive elements. As a result, the coating applied must have excellent anti-corrosion properties. Our company has adopted anodic electrophoretic coating for these antennas, significantly enhancing their corrosion resistance. The salt spray test results show that the coating can withstand over 500 hours without signs of degradation, greatly extending the service life of the equipment. Additionally, this process has improved production efficiency, reducing the cost by 4 yuan per square meter compared to traditional powder coating methods. This not only improves product quality but also enhances overall economic benefits.
**2. Anode Electrophoretic Coating Process**
The anodic electrophoretic coating process for satellite receiving antennas involves several key steps: pre-cleaning, pre-treatment, electrophoretic coating, post-cleaning, and baking.
The detailed process includes:
- Manual removal of release agents from the workpiece surface
- Hot water washing (spray, 120 seconds at 40–60°C using tap water)
- Degreasing (spray, 120 seconds at 40–60°C with cleaning agent and tap water)
- Washing 1 (immersion, 60 seconds at room temperature with tap water)
- Washing 2 (spray, 35 seconds at room temperature with tap water)
- Washing 3 (spray, 35 seconds at room temperature with tap water)
- Pure water washing 1 (spray, 35 seconds at room temperature with pure water having a conductivity of ≤20μs/cm)
- Pure water washing 2 (spray, 35 seconds at room temperature with pure water having a conductivity of ≤20μs/cm)
- Draining (100 seconds with a water blowing station)
- Anodic electrophoretic coating (immersion, 180 seconds at 25–30°C, voltage adjustable from 0–300V, solid content 12.5%, pH 8.0–8.5, film thickness 20±5μm)
- UF liquid rinse
- UF liquid washing 1 (spray, 35 seconds at room temperature with UF liquid)
- UF liquid washing 2 (spray, 35 seconds at room temperature with UF liquid)
- Pure water washing 3 (immersion, 60 seconds at room temperature with pure water having a conductivity of ≤20μs/cm)
- Pure water washing 4 (spray with fresh pure water, counter-flow to washing 3)
- Draining (180 seconds)
- Water blowing (120 seconds manually)
- Baking (30 minutes at 170–180°C using direct-fired gas heating)
- Cooling
**Description of Key Systems:**
(1) The filtration system uses a 4-mesh bag structure with 6 sets, 24 inner bags, and a pore size of 50μm. This ensures high-quality paint film while preventing clogging.
(2) The circulation system includes bath circulation, heat exchange, and ultrafiltration cycles. To maintain bath stability, the bath is circulated 5–7 times per hour.
(3) The ultrafiltration system operates continuously, with inlet pressure between 0.35–0.40MPa and outlet pressure between 0.15–0.20MPa. A separate cleaning system is provided to prevent membrane drying.
(4) The power supply system uses a two-stage energization mode to ensure even and controlled coating.
**3. Control Parameters of the Anode Electrophoresis Process**
**3.1 Voltage**
The electrophoretic system uses a "in-slot energization" method with a two-stage power-on mode. Since the surface area of the antenna is large, the voltage is segmented—initially set at 60–100V to start the coating, then increased to 150–250V once the paint film begins to form. This ensures uniform thickness and prevents excessive buildup, which could affect signal reception.
**3.2 Bath Conductivity**
Bath conductivity directly impacts coating quality. If too high, it causes roughness and poor adhesion; if too low, it reduces throwing power and adhesion. Conductivity is controlled via pure water replacement to maintain optimal performance.
**3.3 Bath Temperature**
Temperature control is crucial. Too high a temperature leads to rough films and faster deposition, while too low reduces viscosity and causes bubbles. The system uses freezing and electric controls to maintain stable temperatures.
**3.4 Electrophoresis Time**
Electrophoresis time is generally fixed, but adjustments may be made by changing line speed. Longer times increase penetration but risk thick coatings, while shorter times reduce corrosion resistance.
**3.5 pH Value**
Anodic electrophoretic coatings are alkaline. Maintaining the correct pH is essential to prevent dirt formation or thinning of the film. pH levels are monitored regularly.
**3.6 Solid Content**
Solid content refers to resins, pigments, and additives in the bath. Too much causes rough coatings, while too little reduces adhesion and increases pinholes.
**3.7 Pigment Base Ratio**
This ratio affects color and corrosion resistance. It is carefully controlled to ensure consistent appearance and durability.
**3.8 Solvent Content**
Solvent levels influence paint solubility and film quality. Proper levels are maintained to ensure smooth application.
**3.9 Baking Temperature and Time**
Proper baking is essential for full curing. Insufficient time or temperature leads to weak, brittle coatings that fail under stress or corrosion.
**4. Conclusion**
In summary, the anodic electrophoretic coating process is meticulously managed through scientific parameter control and regular testing. By adjusting based on test results, we maximize the use of existing equipment and ensure the production of high-quality, durable satellite receiving antennas. This approach not only improves product performance but also enhances cost-effectiveness and long-term reliability.
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