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High Pressure Die Casting

Surface Treatment for Die Casting | Coating, Plating & Painting

A precision die casting is only complete when its surface is protected and finished to specification. Surface treatment for die casting seals porosity, prevents corrosion, and delivers the aesthetic quality demanded by automotive, electronics, and consumer markets. Marcus Hi-Tech’s in-house surface treatment facility handles powder painting, electroplating, and speciality coating — all co-located with our die casting and CNC machining operations for seamless, single-source supply.

How It Works

Step 1: Pre-Treatment & Surface Preparation

All castings undergo degreasing, acid cleaning, and conversion coating before any surface treatment is applied. Correct pre-treatment is the foundation of adhesion — without it, even the best coating fails prematurely in service.

Step 2: Treatment Process Selection

Our finishing engineers recommend the right process based on corrosion class, aesthetic requirement, and end-use environment — powder coating for outdoor durability, electroplating for decorative and functional metallic finishes, or e-coat for uniform coverage of complex geometries.

Step 3: Controlled Application

Each treatment is applied under tightly monitored process parameters — bath chemistry, temperature, film thickness, and cure cycle. In-process checks ensure every part meets specification before moving to final inspection.

Step 4: Testing, Inspection & Despatch

Finished parts are tested for adhesion, coating thickness (XRF), and corrosion resistance (salt spray ASTM B117). Full test records and batch certificates accompany every shipment.

Product

1. Powder Coating

Industry: Electrical, Lighting & Industrial

Description: Thermoset polyester or epoxy powder coat applied to aluminium and zinc die castings for outdoor weathering resistance, UV stability, and impact toughness. Available in any RAL colour with gloss, satin, or matte finish options. Film thickness: 60–80 µm. Salt spray resistance: 500–1,000 hours.

Technical Specifications:

  • Alloys: Aluminium / Zinc
  • Finish: RAL custom / Gloss / Satin / Matte
  • Thickness: 60–80 µm
  • Corrosion: 500–1,000hr NSS
powder Coating

2. Electroplating — Chrome, Nickel & Zinc

Industry: Automotive, Fashion & Consumer Goods

Description:

Decorative and functional electroplating over zinc and aluminium die castings. Copper strike seals micro-porosity before nickel and chrome build-up — delivering Class A automotive chrome, satin nickel, or functional zinc plating for corrosion protection. Meets OEM salt spray and adhesion standards.

Technical Specifications:

  • Process: Copper Strike + Nickel + Chrome
  • Finish Grade: Class A Automotive Chrome
  • Corrosion: 240hr NSS (ASTM B117)
  • Alloys: Zamak 3 / Zamak 5 / Aluminium
Electroplating

3. E-Coat / CED Coating

Industry: Automotive Underbody & Structural

Description:

Cathodic electrodeposition (CED) coating for maximum corrosion protection on complex die cast geometries. E-coat penetrates blind holes, recesses, and internal channels — delivering uniform 20–25 µm film thickness across the entire part surface. Ideal for underbody, chassis, and structural automotive components.

Technical Specifications:

  • Film Thickness: 20–25 µm uniform
  • Corrosion: 500hr NSS
  • Coverage: Full internal & external geometry
  • Alloys: Aluminium / Zinc / Magnesium
  • Availability: High Volume Production

4. Anodizing

Industry: Aerospace, Medical & Consumer Electronics

Description: Type II and Type III hard anodizing for aluminium die castings requiring wear resistance, electrical insulation, or clinical surface quality. Hard anodize (Type III) builds a ceramic-hard oxide layer up to 50 µm thick — significantly increasing surface hardness and abrasion resistance without dimensional distortion.

Technical Specifications:

  • Type II: Decorative / Corrosion Resistant
  • Type III: Hard Coat — up to 50 µm
  • Hardness: Up to 400 HV (Type III)
  • Alloys: Aluminium only
anodizing

5. PVD Coating

Industry: Luxury Goods, Fashion & Architecture

Description: Physical Vapour Deposition for zinc and aluminium die castings requiring premium metallic finishes — gold, rose gold, gunmetal, brushed titanium, and black chrome. PVD delivers scratch-resistant, tarnish-free surfaces with hardness values up to 3,000 HV — far exceeding conventional electroplating durability.

Technical Specifications:

  • Finishes: Gold / Rose Gold / Gunmetal / Black Chrome
  • Hardness: 1,500–3,000 HV
  • Tarnish: Zero — lifetime colour stability
  • Alloys: Zinc / Aluminium
PVD Coating

Testimonial

"One supplier for casting, machining, and powder coat — Marcus Hi-Tech eliminated three separate vendors from our supply chain overnight." —

Rajesh Nair

Procurement Manager, Electrical Equipment OEM

"The chrome finish quality on our door handles matches our Tier 1 OEM spec exactly. Marcus's pre-treatment process is what makes the difference." —

Vikram Iyer

Supplier Quality Engineer, Automotive Interiors

"CED coating on our underbody brackets is uniform across every blind hole and recess. 500-hour salt spray with zero failures across two years of supply." —

Priya Anand

Supplier Development, Chassis Systems

"Hard anodize on our aerospace housings is consistent batch to batch. Hardness values and thickness reports come with every delivery." —

Col. (Retd.) Suresh Menon

Procurement Head, Aerospace Division

"PVD gold on our luxury hardware is indistinguishable from solid gold plating — but it never tarnishes. Our retail return rate dropped to near zero." —

Camille Dubois

Sourcing Head, Luxury Accessories Brand, Paris

Frequently Asked Questions

What surface treatments are available for die cast parts?
Marcus Hi-Tech offers powder coating, electroplating (chrome, nickel, zinc), cathodic e-coat (CED), anodizing (Type II and III), and PVD coating — covering every corrosion, aesthetic, and functional surface requirement across aluminium, zinc, and magnesium die castings.
Which coating is best for outdoor aluminium die castings?
Powder coating with zinc phosphate pre-treatment is the standard choice for outdoor aluminium castings — delivering 500–1,000 hours salt spray resistance with UV stability and impact toughness. Hard anodizing is preferred where wear resistance is also required.
Can zinc die castings be powder coated?
Yes — with correct pre-treatment including zinc phosphate or chromate conversion coating to ensure adhesion. Without pre-treatment, powder coat delamination occurs rapidly in humid or outdoor environments.
What is the difference between e-coat and powder coat?
Powder coat is electrostatically applied as a dry powder and oven cured — ideal for external surfaces and visible faces. E-coat is applied via electrodeposition from a liquid bath, penetrating internal channels and recesses that powder coat cannot reach — making it the preferred choice for complex underbody and structural components.
Do you handle surface treatment for customer-supplied castings?
Yes. Marcus Hi-Tech's surface treatment facility accepts customer-supplied die castings for finishing. We review your drawing, alloy grade, and corrosion class requirements before processing to ensure the correct pre-treatment and coating system is applied.
Where are Marcus Hi-Tech's surface treatment facilities?
Surface treatment is available across our Indian facilities in Coimbatore, Pune, Bangalore, and Chennai, as well as Vietnam (Ho Chi Minh City) and China (Tianjin, Ningbo) — co-located with die casting and CNC machining for integrated, single-source supply.

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