Powder Coating
Powder coating is the process you use to apply a coating without using solvents. This is the newest coating technique in the industry right now. You usually apply this type of coating to create a hard finish on metals and because it allows you flexibility to apply on a different layers of thickness. You would see this finishing in materials such as aluminum, medium density fiberboards, fusion-bonded epoxy and acrylics, usually on automobile finishing.
To produce the powdered finishing, polymer granules are mixed with pigments and powder ingredients. The mixture is heated in an extruder. It is then cooled and rolled flat before being broken into pieces. The chips are then milled to be produced as powder. Given that you can mix any type of pigment into the mixture, the colors you can produce are limitless.
To apply powder coating on an object, you could heat either thermoplastic or a thermo-set polymer material powder and the finishing would make it stick to the usually metallic surface. This may sound like a very tedious process, but what you can do is actually use an electronic gun to spray the powder. The gun gives an electronic charge to the powder causing it stick to the surface. The object is usually heated causing the powder to melt and sticking to the surface producing the hard coating. This is similar to the process of applying to dry paints. The final cured coating is similar to the effects of applying a two-pack wet paint. By giving the object a powder coating, the product ends up relatively hard and abrasion resistant.
There is a possibility for failure. Problems might occur when applying the powder coating. This is due to a lack of preparation. Each product needs different preparation depending on the material of the object. Search online for tips on avoiding these problems.
PEEK Corrosion Resistant Coating? Here’s A ‘PEEK’ At This New Engineered Thermplastic
PEEK corrosion resistant coating, you say? What’s PEEK? This comparatively new engineered family of thermoplastics: PEEK (polyether etherketone), PEK (polyether ketone), and PAEK (polyaryl etherketone) are partially crystalline engineering thermoplastics (plastic polymers) that can be used at high temperatures. These resins have excellent chemical resistance. Their high thermal stability comes from rigid ketone and phenyl groups, while their high strength and thermoplastic state below the decomposition temperatures come from the ether groups.
These compounds can have melting temperatures in excess of 650 degrees Fahrenheit, with mechanical properties retained to about 500 degrees Fahrenheit.
Tensile properties are comparable to most engineering thermoplastics. Creep resistance is outstanding and may sustain large stresses over a useful service life without measurable strain.
Wear rates and friction are becoming increasingly important against metals. Corrosion protection, too, is often an integral part. For these reasons, PEEK (and related polymers) are becoming increasingly important, as demands on them for their structural properties grow, particularly at elevated temperature.
Friction from composites of thermoplastic vary in a unique way from metals in that their asperities (surface irregularity) will deform much more under load. Consequently, friction between a thermoplastic and metal surface is typically characterized by adhesion deformation disproportionally lower to load. The primary mechanism is adhesive wear, which is characterized by fine particles of polymer removed from the surface. This is a good illustration that the surfaces are wearing properly. (Large gouges or corrugations in a polymer surface would suggest not adhesion wear, but abrasion wear or the material’s pressure velocity limit was violated.
Wear factors of PEEK plastics, PEK or PAEK appear much less affected by load and speed components, independent of PV. Wear performance seems to be better at low pressures and high speeds, rather than high pressures and intermediate speeds. All display excellent resistance to wear over wide ranges of pressure, velocity, temperature, and counterface roughness.
Properties of some of the PEEK coating or PEEK plastic plastic are now characteristic of PTFE, PFA, and other corrosion resistant compounds. The advantage is in markets demanding greater resistance to abrasion, higher temperature environments, too. Next time consider PEEK corrosion resistant coating.
That Colorful Coating Paint
IT ADDS color to rooms in our homes, schools, offices and factories. Automobiles and toys are made attractive by it. It protects buildings, farm machinery and tools from the wind, rain, and heat from the sun. Truly, that colorful coating, paint, is enjoying wider popularity than at any time in history.
Thousands of millions of dollars annually are spent for it; Canadians alone lay out almost 200 million dollars a year for paint. In Canada more than 150 paint plants produce this colorful coating. And in the United States over 635,000,000 gallons of paint are sold by manufacturers each year. That is enough paint to cover some 11,400 square miles, or an area almost the size of the Netherlands!
Thousands of Years of Use
The use of paint is not of recent origin. Ancient peoples, particularly the Egyptians, realized that certain pigments found in the soil could be mixed with a liquid and applied to their buildings. For example, colorful reds and yellows were obtained by mixing ochers (natural-colored earths) with water.
Also, pigments were imported from other countries to supplement those found in the Egyptian soil. From the madder roots, which were imported from India, various shades of red, violet and brown were prepared. And from the indigo plant a deep blue color was produced.
Other civilizations were quick to copy the techniques of paint making developed by the Egyptians. Roman artists made use of the same colors and, with few exceptions, the same methods of producing them. However, after the fall of the Roman Empire of the West in 476 C.E. the art of making paints virtually disappeared.
It was near the end of the Middle Ages that the use of paint for decorative and protective purposes began its reemergence in England. At first paints were used chiefly on churches. Then they were used on public buildings and the houses of the wealthy. Since paint was expensive to produce, it was a mark of social distinction to have one’s dwelling painted.
It was not until the 1700’s that paint was made commercially by a few persons who went into the business in the United States and Europe. These early manufacturers produced only the materials for paint; the painter was required to do his own mixing and formulating. It was not until 1867 that prepared paints were first marketed. The development in the late 1800’s of new machines for grinding and mixing enabled paint manufacturers to turn out large volumes of paint, and soon paint making entered an era of rapid development.
The Ingredients
It is estimated now that most paint manufacturers carry an inventory of almost 1,000 different items. Perhaps as many as 500 of these are in daily use. Great strides have been made in the development of new paints. Indeed, not long ago a popular magazine observed: “Eighty-five percent of the paints on sale today didn’t even exist five years ago.” Yet, paint raw materials might be classified into four main groups: (1) Pigments, (2) vehicles, (3) solvents or thinners and (4) additives.
Pigments are the substances that give color and opacity to paint coatings. The ancients frequently used vegetable and animal matter to color their paints, but these are of little importance in paint making today. Still used, however, are earth pigments, called natural or mineral pigments. These are obtained from certain earths that are mined, finely ground and refined. But the most commonly used pigments today are chemical ones.
The vehicle is that part of the paint that carries the pigment. It may consist of oils or varnishes. Drying oils that are used in paint vehicles have the property of converting from a liquid to a solid state when exposed to the oxygen of the air. The paint vehicle thus dries and hardens when it contacts the air. The resulting hard film holds the pigment on the painted surface.
Perhaps the most common thinners for paint are either water or turpentine. These are added to thin the paint to the proper viscosity or thickness for easy spreading on a surface. Although thinners, too, might be considered part of the vehicle, they function somewhat differently in a paint. They begin to evaporate after application of the paint on a surface, leaving the film-forming material exposed for permanent drying.
Paint additives often include compounds of lead, manganese or cobalt. These accelerate the drying of the paint.
How Paint Is Made
Paint is basically a dispersion of colored pigments in a vehicle or liquid medium. The paint maker prepares a rather heavy paste by mixing together dry pigments and a portion of the vehicle. This process might be compared with what a housewife does when she mixes ingredients with her mechanical mixer, perhaps in preparing cake batter. In paint making the mixing cycle is continued until a fluid but somewhat lumpy paste is formed.
The next step requires what is known as grinding. A roller mill of steel cylinders that rotate against each other is frequently used for this. The purpose of the grinding is to pull the pigment particles apart so that each particle will be coated by the resinous vehicle. Another type of mill consists of a revolving drum partly filled with steel balls. By constantly revolving for many hours, the steel balls are able to disperse the pigment particles throughout the vehicle.
After the grinding process, the balance of the vehicle as well as the solvent thinners are added. Also, driers often are added at this time. But when the enclosed steel-ball mill is used, all ingredients generally are included from the beginning. Of course, with the development of water-base paints new types of equipment are used for dispersing pigments and liquids. Tinting of the batch comes next, adding just the proper amount of color to give the batch the exact shade desired. Finally, the paint is moved to automatic machines that fill, cover and code the containers.
The Colors to Use
Since all of us enjoy pleasant surroundings, it will be of interest to consider how you might add pleasantness to your home by employing that colorful coating—paint. Home decorators usually choose colors that will complement other articles in a room, such as those in furniture, rugs or draperies.
Light colors in a small room will create an impression of size, a point to remember when decorating apartments. A continuous flow of neutral tints through several rooms adds an air of spaciousness, inviting one to accent these tints with colorful rugs, cushions or pictures. Keep in mind, though, that an excessive number of colors in any one room can give a cluttered look.
Here are additional helpful hints: Tints of yellow, peach and rose are warm colors. They create a comfortable and mellow charm in rooms facing north and east. Greens and blues in their pastel tones are pages from the marvelous creation around us. One can just feel the cool, relaxing atmosphere imparted by these colors in rooms facing south and west. Rich, bright colors, such as reds and oranges, are exciting colors. But a word of caution. One might tire of them easily. They have a stimulating effect, often reflecting youthful personality or that of one who likes change. Therefore, they often can be suited to the bedrooms of children.
When choosing colors, remember that when a paint is spread over a large area it will appear darker than it does on a small color sample. Therefore, select a lighter shade and it will probably be the color you desire when it is applied to a wall. Also, since colors change under artificial light, it is wise to observe color samples both in daylight and in night light.
Selecting the Proper Coating
Paint is made in a number of finishes, ranging from a high gloss to a flat finish. Generally a low gloss or flat finish will give the most pleasing appearance on a large surface. Flat paints have a greater proportion of pigment to binder, hence they have a rougher finish that scatters the light in all directions. Thus, fewer surface irregularities will show when using a flat paint. However, flat finishes have the shortcoming of being more subject to soiling, and are more difficult to clean.
Thus, if frequent cleaning is necessary, as in a kitchen, bathroom, hallway, or in cupboards and on wood trim, it would be practical to apply a semigloss or highgloss paint. Semigloss would seem to be a compromise that will afford ease of cleaning and will not reflect too many surface imperfections.
In living rooms and bedrooms, a pleasing appearance often overshadows serviceability. Hence a home decorator might choose a flat finish. In the closets, though, where there might be a tendency to mark up the walls, a semigloss paint will make for easier cleaning and a brighter appearance. But since a flat paint has more hiding power and thus often requires but one coat, this is something to consider if time and cost are factors.
Important, too, is the exercise of care in preparing the surface to be painted. Walls and wood trim should be clean before painting. And if the old finish is semigloss or gloss enamel, provide “tooth” for the new application by sanding.
Concrete Coating Solutions
Most everyone that ever had anything to do with concrete knows that it has a wear and tear problem, it is a part of the natural aging of concrete, but what most people don’t know is that this problem can be solved, and sometimes the result can be much better and nicer than ever before. When concrete starts to chip and flake it can be a real eyesore. There is literally tons of concrete that is ripped up and discarded into various landfills every year, yet most of this concrete is still in good structural shape. There are certain exceptions, but most of the visible damage is cracking, and it can be restored with amazing results. The answer to this cosmetic damage is concrete coating. Concrete coating is the natural answer to the aging problems of concrete.
There are various types of concrete coating, each offering different finishes of the final product. The cracks are initially filled, a simple procedure, and then the chipping of flaking (also known as spalling) are removed. Finally a concrete coating is applied to the existing concrete, resulting in a beautiful finish that also resists the corrosive effects of weather. Concrete coating is both strong and durable, lasting years longer than traditional concrete. It is comprised of a unique blend of acrylics and cements resulting in an appealing finish. This procedure of concrete coating allows you to perform a make over to your concrete and upgrade the way your concrete surface.
Another thing that is very important in dealing and maintaining concrete is that concrete coating wouldn’t mean that you have to put in more time and energy into cleaning. Concrete coating is also easy to maintain and proper maintenance can extend the life of the concrete even longer. Maintenance requires pressure washing and simple resealing about every two to three years, depending on the amount of traffic wear and tear. Salt doesn’t affect the coating material and most stains can be easily washed off. Of course one should always be careful when using a snow shovel to not damage the coating. If you use your common sense and experience there is no reason why you shouldn’t enjoy your new concrete coating for a long time, this is really an investment that pays itself in years.
Concrete coating is not only for the outdoors, it is a great solution for any concrete surface, if you want to change the look of your tired, cracked concrete – in a driveway, by the pool, or even indoors – there are many different types of concrete coatings coming in a wide variety of colors. There is even a slip resistant coating available for swimming pools, which really adds safety to the area. Basically any sound surface can be a candidate for coating.
Find out more about concrete coating, it is an amazing way of keeping concrete surfaces and many people find that this is a perfect solution to a tired looking, aging concrete surface.
Coating overcomes hydrogen fuel problems
Adiamond-like coating is making a significant contribution to the development of the hydrogen powered car by providing coating technology to overcome serious lubrication problems.
Poeton Industries, a world leader in surface coating technology, is making a significant contribution to the development of the hydrogen powered car by providing coating technology to overcome the serious lubrication problems posed by the use of the gaseous fuel. Explains Poeton managing director Colin John: ‘Lubrication, or rather the lack of it, was proving to be a serious problem for a major US manufacturer of hydrogen powered internal combustion engines, causing severe wear to valve stems. ‘We were asked if we could provide a coating that would solve the problem and recommended Diamolith, a diamond-like coating (DLC) that has already proved itself in high performance automotive powertrain applications.’ Diamolith adheres extremely well to materials used in automotive manufacture including tool steels, high alloy steels, aluminium alloys, titanium, etc.
Examples of the vulnerable powertrain components that can be protected include pneumatic sleeves, gudgeon pins and piston rings, where Diamolith prevents micro-welding.
Colin John also quotes extreme examples such as the cam followers and front forks of the Hawk Kawasaki Suprbike.
Non-automotive applications include pharmaceutical tablet punch dies, stamping dies, gears and medical components.
Diamolith, which is produced using the plasma-assisted chemical vacuum deposition (PACVD) method, is extremely effective for coating high quality components with complex and varied shapes.
Electrolytic oxidisation transforms magnesium use
A coating process that uses electrolytic oxidisation to transform the surface of magnesium into a hard, dense ceramic oxide, allows the metal to be used in the most demanding environments.
A sample of magnesium coated with Apticote Keronite 3250 SG, a new Apticote composite, has completed a 2000-hour salt spray test with virtually no signs of corrosion. Put into context, the performance of the specialised coating from surface coating specialist Poeton Industries, compares with 150 hours resistance for uncoated magnesium. The result means that magnesium, which is chemically very reactive and therefore highly corrosive, can now be used in the most demanding environments.
The coating process uses electrolytic oxidisation to transform the surface of magnesium into a hard, dense ceramic oxide that is twice as wear resistant and seven times as scratch resistant as anodised surfaces, and is capable of protecting even the most complex shapes without cracking or chipping.
On a standard AZ9ID alloy it can also have hardness of 400-600 HV.
Besides its obvious applications on magnesium, these properties make Magnesium coated with Apticote Keronite 3250 SG an ideal substitute for steel, cast iron, sintered ceramic, even plastic.
Recent applications have included automotive components Cam covers, gearbox housings, roof rails, etc), consumer electronics computers, cameras, mobile phones), erosion-resistant surfaces for textile machinery, frames for mountain bikes, fashion glasses and a wide range of engineering components.
Electrostatic stoving keeps just polished look
To maintain that ‘just finished polished look’ indefinitely for brass cover plates a company has developed a finish that is invisible to the naked eye to avoid constant polishing.
SSK began trading over 30 years ago making metal knobs (the ‘K’ in SSK) for cookers, hi-fi systems and other household goods, but over the years the market has changed and the majority of control knobs are now plastic. During that time SSK has also changed to become a leading manufacturer and supplier of metal electrical wall switch and socket cover plates (the ‘SS’ in SSK). The company makes its cover plates from sheet metal that is sheared to width and cold formed using mechanical presses to produce a range of designs from simple plain cover plates to those with delicate ornate designs around the edges.
The company works in a variety of metals but brass, because of its formability and the ease with which it can be polished to a deep finish, is their and their customers’ favourite metal.
Highly polished brass has always had great aesthetic appeal to architects, designers and end-users, but maintaining that just polished finish without an army of ‘Mrs Mopps’ at the ready with their yellow dusters constantly ‘Brassoing’ is a real challenge.
SSK, working in close collaboration with Indestructible Paints of Birmingham, have risen to that challenge and developed a finish that is invisible to the naked eye but maintains that ‘just finished polished look’ indefinitely.
The finish, which is an electrostatic stoving lacquer, is automatically applied by spray gun, wraps around corners, adheres to edges and is cured by infra-red.
Infra-red curing, which is not the norm for brass lacquers, not only shortens the curing time (drying time) but gives that elusive good depth of finish and a tough hard wearing surface that is less likely to be damaged in subsequent manufacturing operations and when placed in situ.
So good is the finish that any flaw in the polished brass is visible through the lacquer.
SSK is therefore installing an automatic polishing system that will ensure the highest standards of polishing are guaranteed and fully exploits their new electrostatic stoving lacquer.
In conclusion, SSK and Indestructible Paints Company have developed a tough lacquered finish that is less susceptible to damage and requires low maintenance, which is ideal for today’s busy life style, while preserving that just polished look that comes only with wrought brass.
Coating lines benefit from web measurement
One of the world’s leading manufacturers of high performance films and chemicals, has installed innovative web measurement technology in recently commissioned coating lines for industrial films.
Wantage based Autotype, one of the world’s leading developers and manufacturers of high performance films and chemicals, has increased still further its investment in its UK manufacturing facilities, with the installation of new and innovative web measurement technology. Fitted to the company’s recently commissioned coating lines for industrial films used in the electronics, instrumentation and automotive sectors, the new measurement system will enable Autotype to reach levels of manufacturing control that are significantly greater than has previously been possible in high volume manufacturing operations of this kind. Autotype’s Sales Director, Jeff Braham, explains that, ‘The new measurement system is the most advanced of its kind anywhere in the world.
It will enable us to extend considerably the already high quality and performance of our industrial coatings, giving us the ability to control coating thickness and consistency at nanometre levels, or at weights of 0.001 gsm.
We believe that this is the first time that this has been possible in high volume industrial film manufacturing.
Perhaps more importantly, it will help us to provide our customers with an even better level of service, offering products that can be used with confidence at the cutting edge of electronic, optical and electro-optical technologies’.
This innovative system utilises the latest laser technology to determine the precise thickness of single and multi-layer coatings on a wide range of polymer substrates.
One of the key benefits for Autotype is that the web can be scanned across at speeds of up to 3m/sec, enabling the company to monitor and control the thickness of coatings at high output performance.
The newly installed measurement system is just part of an ongoing multi-million pound investment programme at Autotype’s UK manufacturing plant and global headquarters in Wantage, as the company extends its world leading activities in specialty high performance films for electronics, film insert moulding and flat panel display screen markets.
Expansion of coating facilities Planned For 2004
In light of its planned expansion of facilities, specialists in the application of coatings onto plastics will be showing product samples at the UK’s Southern Manufacturing show.
Applied Coating Technologies has committed itself to an expansion programme of its coating facilities during 2004. Specialists in the application of coatings onto plastics, product samples will be on show at Southern Manufacturing 18-19 February, 2004. The expansion programme for 2004 includes: * The procurement of a Staubli 6-axis robot, purposely designed to recognise over 200 different parts, thus allowing even small-medium volume production runs to be automated.
Robotic spraying offers many advantages over manual production including increased throughput, greater consistency and repeatability and more control over paint usage.
The robot will be housed in a fully enclosed water-back spray room to allow both conductive paints for EMI shielding and decorative paints for cosmetic finishing to be sprayed.
* The installation of a second custom-designed clean-room spraying facility for the application of cosmetic finishes.
This plant has been specifically designed to provide high-quality surface finishes.
With fully integrated de-ionisation and product curing facilities, typical paint defects such as air-borne ‘inclusions’ have essentially been eliminated from the process.
Therefore a complete range of matt to gloss finishes can be achieved.
* A further three dry-back spray booths have been installed to increase the capacity of ACT’s EMI Shielding business.
ACT offers nickel, copper and silver loaded paints for EMI Shielding and is now the UK’s largest solutions provider for EMI Shielding.
The development of decorative finishing at ACT was in response to customer requirements for a one-stop shop finishing service.
Future developments planned, involve adding secondary finishing processes to our product range, such as pad printing.
Samples of contemporary finishes currently available at ACT such as satin chrome / stainless steel / soft feel effects will be on show at Southern Manufacturing.
The core business of ACT is EMI shielding coatings and examples of components coated with conductive paints and electroplating techniques will also be on show
Polyamide for automotive panels electro-paintable
Electro-paintable polyamide grade, not requiring conductive primers, is designed for vertical body panels withstands the e-coat temperature up to 200degC for a 30 minute oven cure.
Rhodia Engineering Plastics has announced the introduction of Technyl A 238P5 M25 blk 5N. This new grade has been specifically designed to meet the critical technical requirements for automotive vertical body panels. The technical characteristics of Technyl A 238P5 M25 meet the requirements for a better performing material at high temperature and, in particular, with respect to the e-coat process temperature increase announced by many car makers for the near future.
Parts made of Technyl A 238P5 M25 such as front fenders can then be assembled prior to the electro-coating bath (on-line process) and successfully pass through the curing oven at a temperature of around 200degC for 30 minutes.
Successful sag test results, up to 220degC, demonstrate the substantial advantage of Technyl polyamide performance versus other thermoplastic competitive materials.
The excellent thermal resistance of Technyl A 238P5 M25 is due to a pure PA66 polymer matrix modified with specific fillers.
Technyl A 238P5 M25 can be painted by using electrostatic painting systems without conductive primers.
Parts made of this new Technyl grade exhibit a high paint transfer efficiency resulting in VOC emissions reduction as well as cost savings.
The paint thickness uniformity observed with large parts results from a low variation in volume and surface conductivity thanks to the specific technology developed by Rhodia, and is an additional benefit of this new product.
Technyl A 238P5 M25 confirms the typical advantages of plastics exterior body panels applications in comparison to metals: - Weight reduction up to 40% vs steel - Better low speed impact behavior - Design flexibility and more opportunity for complex parts design - Good chemical resistance - No corrosion Furthermore Technyl A 238P5 M25 offers specific advantages vs other thermoplastic materials in use for such applications: - Improved heat resistance - Better dimensional stability due to a lower CTLE - Easy processing on standard injection molding machines - Better productivity through the reduction of injection moulding cycle time and lower part reject rate - Mold design simplification Technyl A 238P5 M25 has been successfully tested on parts such as exterior front panels.
The parts were submitted to the typical automotive standard tests including: - Resistance to e-coat process up to 200degC for 30 minutes and dimensional shrinkage evaluation.
* Electrostatic painting on production line and measurement of the surface aspect.
The parts were submitted to e-coat, painted, and then dried at a typical temperature of 140 to 160degC for 20 to 30 minutes.
* Adhesion tests using the most common automotive painting systems.
Parts were submitted to water immersion, thermal shock, jet of hot water at high pressure, etc - Impact test at room temperature and low (-20C to -30C) temperature conditions.
Rhodia Engineering Plastics is promoting Technyl A 238P5 M25 for both in-line and on-line painted parts, for example: vertical panels, fuel filler flaps, rocker pillars, front grills, and exterior trim applications.
Rhodia Engineering Plastics can support its’ customers in the development of new applications through its’ technical application developments centers worldwide.
Appropriate support is available from the concept to the production of body panels including assistance with mould design, CAE, process optimization and testing on components.
Rhodia Engineering Plastics, headquartered in Lyon, France, is the world wide specialist in polyamide engineering thermoplastic materials.
The company has a sales network that spans the world, with manufacturing plants and technical development centres in Europe, North America, South America and Asia.