<![CDATA[The coating industry is shifting from solvent-based to water-based paints due to lower Volatile Organic Compound (VOC) content, making them more environmentally friendly. However, water-based paint film characteristics are highly sensitive to workpiece temperature and spraying pressure, requiring careful process parameter evaluation to achieve optimal coating quality. This experimental study employed spray coating on SS400 steel and aluminum with varying workpiece temperatures (30°C, 40°C, 50°C) and spraying pressures (2.0, 2.5, 3.0 bar). Coating hardness was measured using a durometer (Shore A, ASTM D2240) and adhesion via cross-cut test (ASTM D3359); data were analyzed using two-way ANOVA (α = 0.05). Hardness on SS400 steel increased from 84.5–86.5 HA at 2.0 bar to 89.5–91.5 HA at 3.0 bar; on aluminum, from 85.5–87.0 HA to 92.0–94.0 HA. Adhesion on SS400 improved from 2B to 4B–5B, and on aluminum from 1B–2B to 4B–5B across the same pressure range. Workpiece temperature was the most dominant factor influencing both hardness and adhesion, while spraying pressure significantly affected hardness but not adhesion. Optimal coating quality was achieved at 50°C and 3.0 bar. Precise control of both parameters is essential for producing high-quality water-based paint coatings on metallic substrates. ]]>
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