<![CDATA[SS400 steel lacks significant protective alloying elements, requiring an epoxy-aluminium coating whose effectiveness strongly depends on the adhesion strength between the coating and the substrate, with both adhesion and coating thickness affected by spray distance. This study aims to analyze the effect of spray distance variation (50, 100, and 150 mm) on the adhesion strength and thickness of an epoxy-aluminium coating applied to SS400 steel. A quantitative experimental method was employed, comprising surface preparation via sandblasting with 50/80 mesh glass beads, air spray application of the epoxy-aluminium coating, and testing of adhesion strength using a pull-off test (ASTM D4541-22) and coating thickness using a Dry Film Thickness gauge (ASTM D7091). The results show that adhesion strength increased with spray distance, from 9.1 MPa at 50 mm to 10.1 MPa at 100 mm and reaching the highest value of 10.9 MPa at 150 mm, while coating thickness decreased monotonically from 61.1 μm to 44.8 μm over the same range. A spray distance of 150 mm produced the highest adhesion strength together with the thinnest coating among the tested distances, and is therefore recommended as the best application parameter within the 50-150 mm range]]>
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