| Carbon Steel | Two-component epoxy primer | Polyamine or modified amine adduct | Usually 10–40% of total mixed binder, according to the supplier’s equivalent ratio | Good adhesion, chemical resistance, and ambient-temperature cure; pot life commonly 1–8 hours at approximately 25°C | Remove oil, rust, and mill scale; abrasive blast to a clean, profiled surface or mechanically prepare to an equivalent standard | Strong corrosion-protection platform and good compatibility with anticorrosive pigments | Incorrect stoichiometry can cause soft films, poor adhesion, or excessive brittleness |
| Galvanized Steel | Adhesion-promoting epoxy or epoxy-modified primer | Low-yellowing amine adduct or compatible waterborne epoxy curing agent | Commonly 15–35% of total mixed binder; confirm by epoxy equivalent and amine hydrogen equivalent | Requires controlled reactivity to reduce intercoat defects and improve adhesion to zinc surfaces | Degrease thoroughly, remove white rust, and lightly abrade or sweep blast without removing excessive zinc | Good adhesion when the surface is clean and lightly profiled; suitable for maintenance and fabrication coatings | Strong solvents, excessive abrasion, or a highly acidic formulation may damage the zinc layer |
| Hot-Dip Galvanized Sheet | Thin-film epoxy or epoxy-polyurethane adhesion primer | Modified polyamine with moderate cure speed | Typically 10–30% of total mixed binder, subject to the selected epoxy resin | Low-shrinkage cure and good wetting are more important than maximum hardness | Remove passivation residues and processing oil; use a non-aggressive abrasion method where permitted | Balances adhesion, flexibility, and corrosion resistance on relatively smooth zinc-coated surfaces | A fast-curing agent may reduce wetting and create cratering or poor intercoat adhesion |
| Aluminum | Epoxy, epoxy-polyamide, or specialized epoxy adhesion primer | Flexible polyamide or amine adduct with good wetting | Often 15–45% of total mixed binder, depending on resin functionality and flexibility requirements | Good wetting and moderate flexibility help accommodate aluminum’s thermal movement and oxide layer | Degrease, remove oxide contamination, and abrade or chemically pretreat; coat promptly after preparation | Improves adhesion to the oxide-covered surface while maintaining useful impact resistance | Overly rigid or highly exothermic systems can crack, shrink, or lose adhesion during thermal cycling |
| Stainless Steel | High-adhesion epoxy primer | Modified amine adduct or polyamide curing agent | Generally 15–40% of total mixed binder, calculated from the resin and curing-agent equivalents | Requires strong wetting and sufficient mechanical or chemical bonding to the passive oxide layer | Remove oil and fingerprints; abrade with clean, dedicated media to avoid iron contamination | Provides a sound base for subsequent protective or decorative coating layers | Poor preparation can cause rapid delamination even when the cured film appears hard |
| Copper and Copper Alloys | Epoxy primer with good barrier performance | Low-yellowing amine adduct or polyamide | Commonly 15–40% of total mixed binder, with compatibility confirmed by laboratory testing | Good barrier properties and controlled cure are preferred to minimize staining and surface defects | Remove oil, tarnish, and soluble salts; lightly abrade and apply soon after cleaning | Can provide durable adhesion and isolate the substrate from moisture and aggressive environments | Some pigments, amines, and contaminants may contribute to discoloration or interfacial adhesion loss |
| Zinc-Rich Steel Primer | Inorganic silicate or compatible epoxy zinc-rich primer | Moisture-cure silicate system or amine curing agent for epoxy zinc-rich systems | Follow the binder-specific ratio; zinc-rich formulations should not be adjusted by simple volume substitution | Cure depends strongly on humidity, temperature, pigment loading, and film thickness | Prepare steel to a high cleanliness level and control surface profile and humidity before application | Provides barrier protection and, in suitable systems, sacrificial zinc protection | An incompatible curing agent may interfere with electrical contact between zinc particles or cause mud cracking |
| Metal with High Flexibility or Thermal Cycling | Flexible epoxy or epoxy-modified coating system | Polyamide or flexible amine adduct with extended cure profile | Often 15–45% of total mixed binder, adjusted to balance flexibility and hardness | Lower crosslink density generally improves flexibility but may reduce solvent and chemical resistance | Use a clean, dry, profiled surface and verify that the primer can tolerate the expected movement | Reduces cracking and delamination risk caused by impact, vibration, or temperature changes | Excessive flexibility may produce blocking, low hardness, or reduced resistance to aggressive chemicals |