Anti-corrosion electrocoat

A process for the coating of a ferrous substrate comprising the steps of:

• 1) providing a first bath comprising a conductive pigment-containing electrocoat composition;
• 2) placing the ferrous substrate at least partially into the first bath;
• 3) passing an electric current through the first bath and the ferrous substrate to deposit a layer of the conductive pigment-containing electrocoat composition onto at least a portion of the substrate;
• 4) removing the ferrous substrate from the first bath;
• 5) rinsing the coated substrate with water;
• 6) heating the ferrous substrate to cure the applied layer of conductive pigment-containing electrocoat composition;
• 7) providing a second bath comprising a second electrocoat composition;
• 8) placing the ferrous substrate at least partially into the second bath;
• 9) passing an electric current through the second bath and the ferrous substrate to deposit a layer of the second electrocoat composition onto at least a portion of the layer of conductive pigment-containing electrocoat composition;
• 10) removing the coated substrate from the second bath;
• 11) rinsing the coated substrate with water;
• and
• 12) heating the substrate to cure the applied layer or layers of electrocoat composition,
• wherein the conductive pigment-containing electrocoat composition comprises:
• A) a pigment, consisting of conductive pigment;
• B) an epoxy resin;
• and
• wherein the conductive pigment-containing electrocoat composition has a pigment to binder ratio in the range of from 0.1:1 to 1:1.