Surface Finishing Processes Compared
Side-by-side comparison of anodizing, powder coat, liquid paint, plating, and blasting.
Anodize aluminum for corrosion and hardness; powder coat or plate steel; high cosmetics favor paint or nickel; wear-critical aluminum uses hard anodize (HV300+).
1Anodizing (aluminum)
Standard anodize 5–25 µm, HV200–300, good salt spray. Hard anodize 25–75 µm, HV300–500, excellent wear. Color anodize for cosmetics.
2Powder coating
For steel and aluminum. Film 60–120 µm, strong salt spray, economical in volume. Full RAL palette, matte or gloss.
3Plating
Zinc for corrosion; nickel for decoration and corrosion; hard chrome HV900+ for extreme wear. Account for plating thickness on fits.
4Blasting and brushing
Blast removes burrs and scale, Ra 0.8–3.2 µm, improves adhesion. Brushing is decorative on stainless/aluminum, often combined with anodize.
Key points
- Aluminum + wear → hard anodize
- Steel high volume → powder coat
- Cosmetic parts → paint or nickel
- Precision fits → reserve plating allowance
- Outdoor parts → anodize or hot-dip galvanize
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