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The electrocoat operating windows of five automotive sheet steel products (uncoated cold rolled, electrogalvanized, hot dip galvanized, electrogalvanneal, and hot dip galvanneal) were compared. The effect of variations in base steel chemistry and galvanneal coating structure on the operating window were also evaluated. While all variations exhibited an acceptable electrocoat operating window, there was a measurable difference between the five sheet steel products. There was no effect of the galvanneal coating structure or base steel chemistry on the operating window.

The automotive industry is currently expanding the use of precoated metals and cathodic electrocoat primer on passenger and truck vehicles for corrosion upgrade. During the electrodeposition process, rupturing occurs on various precoated metals resulting in defects which decrease appearance and corrosion protection. Laboratory and field investigations have uncovered contributing factors which increase the frequency and severity of rupturing under assembly plant conditions.