Composite Ceramic Coatings Specifications

Series 100 
For Aluminum & Magnesium

Coating Specifications

Suitable Alloys

Series 100 coatings are suitable only for aluminum and magnesium substrates. To optimize coating performance, low copper alloys (less than 5%) and low silicon (less than 7%) are preferred.

Coating Thickness

Coating thickness for our Series 100 coatings consist of both surface penetration and real dimensional growth. Typical thickness is 0.002 inch (per surface), which consists of an increase in the surface dimension of approximately one-half this thickness or 0.001 inch (per surface). Standard process tolerance is ±0.0004 inch (real surface growth of ±0.0002 inch) for most alloys. Depending on your dimensional requirements, lower and higher builds are attainable and can be specified for the majority of our Series 100 coatings.

Precise process control and coating uniformity permits coating of close tolerance dimensions, threads, and holes. Blind holes coat the same as exterior surfaces if the depth does not exceed approximately 1.5 times the hole diameter, and through holes will coat uniformly if the depth does not exceed approximately 3 times the diameter.

Surface Finish (RMS)

Our Series 100 coatings will typically increase the RMS surface roughness on wrought alloys between 5 to 15 micro-inches and between 20 to 60 micro-inches on cast alloys. Although the increase in roughness is significantly offset with our polymer infusion, we recommend that you finish to an RMS value better than required.


Micro surface hardness approaches that of case-hardened steel. Typical micro surface hardness ranges from 45 to 70 Rc, depending on the aluminum alloy substrate and the specific Series 100 coating being applied.

Wear and Abrasion Resistance

Series 100 coatings are dense with low porosity, therefore exhibiting superior abrasion resistance even when compared to hardened tool steel.

Low Friction

Series 100 coated surfaces are uniform, conformal and smooth, and may be further supplemented through the impregnation of low friction, high release fluoropolymers. With the introduction of these chemistries, our Series 100 coatings can afford extremely low coefficients of friction. Values will vary depending on the specific chemistry/coating being applied, however; they typically range between 0.08 and 0.15. The amount of friction reduction is application and compound specific.

Chemical & Corrosion Resistance

Our Series 100 coatings are chemically resistant to a variety of chemicals and exhibit exceptional corrosion resistance. The majority of our Series 100 coatings will withstand 336 hours of salt spray exposure, with some systems affording over 1,500 hours of protection (per ASTM B117). To ensure that we specify the most appropriate corrosion resistant coating for your use environment, MSDS sheets may be requested by our technical consultants for review.

Non-Stick/Release Properties

Through a proprietary vacuum impregnation process, Endura® can integrate specific high release fluoropolymers into the majority of our 100 Series coatings. These fluoro-chemistries provide exceptional non-stick surface characteristics, affording sustained high release properties from a variety of materials and tactile products.

Operating Temperature Range

Our Series 100 coatings can withstand severe temperature fluctuations with little loss or no in physical properties. These coatings are designed to operate from cryogenic to 450°F continuous operating temperatures (500°F intermittent exposure). Select coating systems within our Series 100 coatings are even thermally stable at continuous operating temperatures up to 900°F.

Thermal Properties

Coatings within our Series 100 technology platform possess low thermal conductivity and provide outstanding insulating properties far superior to that of uncoated aluminum and magnesium substrates.

Electrical Properties

Series 100 coatings possess high dielectric strength over a wide frequency range, a low factor for dissipation, very high surface resistivity, and have insulating capabilities to withstand up to 2,000 – 3,000 volts/mil, depending on coating thickness and the specific Series 100 coating being applied.


Series 100 "Infused Matrix" coatings can repel both water and oil. They resist wetting by most liquids. Clean-up is easier, more thorough, and in many cases reduced or eliminated.

Critical Processing Factors

Racking Area

To create our Series 100 coating architectures, your parts must be fully submerged into an electrolytic bath. As a result, fixture points of contact are required to securely hold and suspend your tooling during processing. Areas where we make contact with you parts will have small racking voids and should be located on your parts non-functioning (non-working) surfaces. Prior to sending in tooling for processing it is important to have acceptable surfaces for racking defined so as to ensure our manufacturing and production team run your parts to your specifications.


Masking of select surfaces where coating voids are required is available. Endura® works with a variety of mediums to mask surfaces where coating is not desired. Depending on your part’s geometry and surface characteristics painted-on lacquers, pull-plugs, and custom fabricated fixtures may be used to accomplish the aforesaid. In the event masking is required, highlighted or “marked” prints identifying critical surfaces are extremely helpful in ensuring your parts are processed to spec.

Please complete our Coating Requirement Questionnaire
or call us at 1.800.336.3872 to review & discuss your project requirements.

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