Facility ensures high quality moulding finishes
Fully enclosed water-back spraying facility for the application of cosmetic finishes to medium production volume plastics mouldings provides a high-quality surface finish.
Applied Coating Technologies (ACT) has recently installed a fully enclosed water-back spraying facility for the application of cosmetic finishes. This plant has been specifically designed to provide a high-quality surface finish to plastic mouldings, increasing the perceived value of any product. ACT’s new facility has been purpose-built to serve low-medium volume manufacturers.
Our customers now benefit from an ‘automotive standard’ finish without suffering a second-class service on delivery.
Adding value by decoration allows the product lifecycle to be extended and can reduce injection moulding costs.
Many ACT customers manufacture their bulk orders in virgin plastic and satisfy individual customer/market demands for particular colours by paint-spraying; hence moulding set-up and masterbatch costs are kept to a minimum.
Excellent adhesion, abrasion resistance and durability are achieved onto ABS, Noryl, Polycarbonate and other similar thermoplastics.
Although a wide range of gloss levels are available, satin/matt finishes are usually specified as these produce very low scrap levels and are currently in vogue.
Contemporary paint finishes include stainless steel/satin chrome effects.
Where greater chemical resistance and exterior durability are required, two-pack polyurethane top-coats are recommended.
These have been developed in smooth, spatter and textured (including soft-feel and suedette) finishes.
With adhesion promoters available for even the most difficult substrates (polypropylene, nylon), paint finishes can be applied selectively onto most plastic or metal surfaces.
Specialist knowledge in the design of high precision masking jigs is regarded as an essential area of expertise.
Selective coatings have a number of benefits; they can reduce cost, increase the affect of a particular finish and protect critical mechanical tolerances.
The development of decorative finishing at ACT was in response to customer requirements for a one-stop shop finishing service.
The core business of ACT is EMI shielding coatings.
Free booklet commemorates Cadmium Centre opening
To mark the opening of a Cadmium Centre, Poeton has produced a new 30-page booklet explaining benefits of the cadmium process, which stands alone as a superior anti-corrosion coating.
Poeton Industries has created a Cadmium Centre at its Cardiff plant following the installation of a new LHE cadmium process. Poeton Cardiff Technical Manager Chris Rochelle, who is also the group’s senior cadmium technologist, says that when added to the existing bright and dull cadmium capabilities, the LHE capability provides customers with the complete range of cadmium processes on a single site. He adds that all the processes operate in a zero discharge environment, ensuring that no waste escapes the site’s sophisticated waste control system.
To mark the opening of the Centre, Poeton has produced a new 30-page booklet explaining the benefits of the cadmium process which, the company says, stands alone as a superior corrosion resistant coating for manufactures of aerospace and defence equipment.
The booklet is available free of charge by calling 029 20 388182 or emailing chrisrochelle@poetonc.demon.co.uk.
Summarising the benefits Chris Rochelle says cadmium coatings can be applied to a wide variety of surfaces.
They also provide a combination of outstanding corrosion resistance, low friction coefficient and electrical resistivity, good galvanic comparability and plating coverage, and are easily brazed and soldered.
‘For these reasons’ Chris says, ‘cadmium coated products are preferred for a wide range of critical and safety-related applications in the aerospace, electrical, and defence industries.
Porosity detection and sealing services approved
Specialised pressure testing to detect metals porosity and impregnation sealing services have been granted BS EN ISO 9000:2000 and aerospace approval AS9100 approvals.
The Ultraseal Slough based Division of Surface Technology, recently announced the successful granting of BS EN ISO 9000:2000 and aerospace approval AS9100 for its Slough based operating division. This follows the granting of the industry approvals for impregnation and pressure testing of aerospace and general engineering components, shown below. The current approvals follow the acquisition of the assets related to the impregnation and pressure testing activity of Metalseal Limited and they include approvals from: Westland Helicopter; Airbus UK; Raytheon; Honeywell and Goodrich Actuation.
Mark Ward - production manager of Surface Technology’s Slough based division said: ‘These approvals ensure that we stay at the forefront of surface finishing and associated services.
We at Slough are the first unit in the UK to be granted all necessary approvals required by aerospace customers in particular relating to impregnation processes’.
‘As microporosity is a small defect with the potential to become a big problem, we perform pressure tests and subsequently apply our Ultraseal technology in order to eliminate future problems ‘.
Therefore Surface Technology, Slough is now offering the following services: Pressure Testing - why Pressure Test?
Few manufactured products can be considered to be absolutely free of porosity.
Even the presence of minute porosity can lead to the permeation of gasses through metals, crystals, polymers and glass.
Leak detection is based on finding if a component leaks more than the allowable limit under specified conditions.
Test conditions must be carefully specified as they could reduce the performance of the test and add extra cost.
Test or not to test?
In the manufacturing cycle, the earlier a leak is detected, the less re-working that needs to be carried out and therefore the process will become less expensive.
The component may be tested several times during manufacture, on its own and then as part of an assembly with the possibility of a service test of the final build standard.
Types of tests available - there are various types of physical tests, which can be used to detect, measure and locate leaks.
The best test for each component is one that will provide you with the numerical and physical data e.g rate and location of a leak.
Several military agencies and a few industrial groups have developed specific methods and procedures for performing leak tests.
We are approved to carry out most of these.
The following types of pressure test procedures are offered at our Slough facility: * Air under Water.
* This test method is best suited to large production runs or where batch or percentage testing is required up to 100 psi.
The components are placed on a test bed and clamped down.
All apertures are suitably sealed.
The test bed is lowered into the water tank and the air is introduced into the casting.
A leak can be visually identified by the presence of bubbles.
* Air-under-water is optically sensitive and an inexpensive method of leak detection.
* Components measuring 4ft x 2ftx 1ft can be tested on one of our two pressure testing machines using a three-way clamping system.
* Hydrostatic testing.
* When castings are too large to be immersed, they can still be tested.
using water, or another suitable medium.
The casting is banked-off, leaving one entry point to introduce the liquid medium.
After filling the casting, the last aperture is sealed.
Pressure is then applied using a pump and reservoir system.
Depending on the wall thickness and pressure being used, the casting is then examined for leakage.
This is usually seen as beading on the surface or a continuous jet depending on the severity of the leak.
* Ultraseal, the Slough based unit of Surface Technology plc, are able to hydrostatic test any sized component up to 300 lb/in2.
* Hydraulic Testing.
This test method is better suited for higher pressure resistant components or where a customer requires the use of a specific medium, for example water, hydraulic fluid, kerosene or even Ultraseal’s own resin.
The test piece is blanked off using suitable equipment, bearing in mind that the higher the pressure the more complex the jig will need to be.
The test medium is added and then bled to remove any air pockets.
The pressure is then increased to the required level.
If a component then leaks the location is easily recognised.
Ultraseal are able to test up to 10,000 lb/in2 hydraulically using customer supplied jigs or Ultraseal can have them manufactured at one of our sister engineering companies.
Impregnation - why Impregnate?
* To check if components leak we can Pressure test them.
* To reduce moisture entrapment and to prevent leaks.
* To improve integrity of welds on cast iron and aluminium substrates.
* To reclaim expensive castings and fabrications that would otherwise be scrapped due to leakage.
* To prevent ‘Blow Out’ of entrapped gases during subsequent plating or painting processes.
What is Ultraseal?
* Ultraseal is the sealant used in the impregnation process.
* Ultraseal will treat any size component with a resin formulation.
* Ultraseal is a process, which fills voids and micro-porosity in a wide variety of materials.
* Ultraseal is designed to ensure full compatibility with various substrates including aluminium, magnesium, cast iron and steel, carbon fibre composites, GRP mouldings and plastics The impregnation process - chromate Conversion - what is Chromate Conversion?
To achieve their full protective properties on Aluminium alloys, most organic coatings require the metal surface to be pre-treated to provide a surface film, which becomes an integral part of the metal surface involving virtually no dimensional change.
These conversion coatings form an ideal substrate for paints and precious metals, providing a clean, essentially inert surface, which gives optimum adhesion.
Most organic coatings applied directly to Aluminium surfaces will not adhere well, and if subjected to any deformation, they will tend to flake off exposing the bare Aluminium.
Scratching off the paint surface would also provide a nucleation site for Aluminium corrosion and further undercutting of the coating.
The answer! A pre-treatment is therefore required which can be applied to Aluminium to provide a suitable basis for subsequent coatings.
Conversion coatings have been developed which can be used on aluminium alloys and which are compatible with most paint systems.
These coatings are so named because surface film is formed by a chemical reaction.
As a result of this reaction and conversion the film becomes an integral part of the metal surface, exhibiting excellent adhesion properties.
Applications - the application for chromated aluminium can cover a wide range of functions.
Conversion coating can provide mild wear resistance, better drawing or forming characteristics and may be used to provide a decorative finish and is also ideal for pre-treatment prior to powder coating.
The Process - the successful application of this conversion process requires the aluminium to be clean and free from organic soils, oxides and corrosion products.
We can clean or degrease the component as an additional service at Slough.
What can the Surface Technology, Slough based Ultraseal division offer from the S6000 series of Process Codes?
* Code 6400/Alocrom 1200.
* This gives good electrical conductivity with excellent corrosion resistance, providing an excellent base for paint.
Process Tank Size: 900mm x 600mm x 600mm.
* Code 6500/Alocrom 1000.
* Particularly suited for high electrical conductivity.
* Process Tank Size: 900mm x 600mm x 600mm.
* Code 6600/Alocrom 100.
* Often specified for construction parts and is an excellent base for paint that can be left un-coated.
* Process Tank Size: 3m x 300mm x 600mm.
* Code 6800/zinc passivate.
Iridescent conversion coating on matt or bright zinc or cadmium deposits and on zinc die-casting.
Process Tank Size: 900mm x 600mm x 600mm.
Ask for our latest Data Sheets or our free Process Code Directory on a CD-Rom disk.
Gel simplifies metal blackening operation
Gel for preparing iron and steel substrate parts simplifies the metal blackening operation for finishing prototype and short run metal fabricated parts, cutting tools, moulds or dies.
Birchwood Casey announces introduction of its new Presto Black Gel for iron and steel substrate parts. Designed for use on any size part in limited quantities, the new Gel solves the application challenges of liquid products while producing an attractive, high quality, durable black finish. New Presto Black Gel simplifies the metal blackening operation.
After cleaning the part surface in the normal manner to remove cutting oils, coolants, etc, the user simply swabs on a layer of Presto Black Gel with a synthetic paintbrush, then allows the Gel to work for two to ten minutes.
The Gel adheres to the metal surface and blackens uniformly without running off - even on vertical surfaces.
With most parts, no re-application of the Gel is necessary.
When the desired depth of black is achieved, the Gel is simply rinsed off in the normal manner, leaving behind an invisible protective finish that inhibits water-spotting and corrosion during drying.
The resultant black finish is clean and tightly bonded to the metal substrate, and can be sealed with Birchwood Casey Dri Touch3 PLUS IRP3 non-tacky rust preventive for maximum service life.
Ideal for finishing prototype and short run metal fabricated parts, Presto Black Gel can be used for blackening sharpened cutting tools, for molds, dies, and on previously blackened parts that have been re-machined.
The Presto Black Gel also works well on platens, machine tables and fixturing devices that require re-blackening as part of maintenance or overhaul.
This re-blackening can be done without disassembly of components when necessary.
Presto Black Gel provides a new, more efficient finishing option to manufacturers using immersion or brush-on finishing processes.
While immersion tank lines are most economical in production-scale operations and brush-on techniques prevail in shops dealing with large workpieces and small part quantities, the Presto Black Gel process provides both of these manufacturers with a faster, cleaner and more cost-effective alternative.
Large workpieces using liquid blackeners, for example, are challenging to work with due to difficulties of applying the liquid to a large surface uniformly.
Another problem is minimizing the runs and drips during the finishing cycle and re-applying the liquid where needed to carry the blackening process to completion.
Following blackening, these workpieces need careful rinsing and drying to avoid any tendency to waterspot or corrode.
Each of these steps can reduce the level of operator control needed to achieve satisfactory results.
By contrast, the new Presto Black Gel simplifies the process and eliminates most of these problems.
Presto Black Gel is available in 1 gallon and 5 gallon containers ready for easy application.
Manual powder coating system control at fingertips
Manual powder coating system has fingertip controls on its air gun that instantly activate a range of options and a 12-stage, high voltage cascade offers even greater transfer efficiency.
The new Mach-Jet manual powder coating system from Sames has been designed to outperform its competitors in virtually every respect. Fingertip controls on its air gun instantly activate an unmatched range of options. A brand new 12-stage, high voltage cascade offers even greater transfer efficiency, believed to be the best currently available.
Mach-Jet is controlled completely electronically making it immune to the variability of pneumatic operation.
It is also one of the most balanced and lightweight systems on the market - 660 grams - and despite all these credentials, it is also eminently affordable.
The mobile Mach-Jet will specifically appeal to companies wishing to optimise their powder coating application.
The main focus of the system’s flexibility is in its gun that gives single-handed control of four pre-selected spray settings and up to 12 levels of powder flow.
The operator can instantly switch between high Volt/micro Amp settings for fan spray, round spray, re-coating and metallic powder.
The setting selected is illuminated on the gun’s display as an easy-to-read icon.
This level of capability is not available on any other system.
This is not a totally airless system and is completely plc-controlled; a feature unique to Mach-Jet.
Other features that make the gun so easy and effortless to use are a hose swivel - which also prevents kinking - and a choice of two sizes of soft handgrip to accord with the operator’s hand size.
The system’s powder pump actively aerates the powder as it is delivered to the gun, ensuring consistent and reliable flow.
This is complemented by a particle filter that removes any airborne moisture.
The pump also features a new quick release hose coupling that allows fast colour change and cleaning.
Plugs and hoses are colour-coded for easy assembly.
To ensure that the optimum electrostatic charge is selected to suit the part and the powder, all the settings are programmed and adjusted via Sames’ new, compact CRN 457 controller.
This is an intuitive system that is designed for simple and speedy, icon-driven programming.
This controller is integrated into the front of the cart and mounted on an incline to give the operator good visibility of the display.
The streamlined cart is manufactured completely from heavy duty plastic.
This makes it easy to manoeuvre and to clean.
It is also designed so that all system elements have a secure location and to provide additional storage for parts, nozzles etc Two versions of Mach-Jet are currently available - with vibrating table for box feeding or with 36-litre fluidised bed for hopper feed.
A pressure pot option is scheduled for release during the summer.
Metal coating process is non-toxic
A new, environment and user-friendly metal coating process for iron and steel components forms a non-toxic aluminum oxide conversion coating and can be used in high-heat applications.
A new, environment and user-friendly metal coating process for iron and steel components, called Microlok AO, has been introduced by Birchwood Casey. The patent-pending immersion tank process works on all iron and non-stainless steel surfaces. It forms a non-toxic aluminum oxide conversion coating that is 0.000040 inches (1 micron) thick that is tightly bonded to the part surface.
It has an attractive silver-black color.
When sealed with a rust preventive topcoat, the Microlok AO coating protects parts during storage and shipping and provides break-in lubricity and anti-galling protection.
Unaffected by temperatures as high as 1400deg F, the Microlok AO finish can be used in high-heat applications and also serves as an excellent base for paint finishes or other topcoats, outperforming iron phosphate coatings.
Unlike acidic and caustic finishing processes, the Microlok AO process uses a mild (pH 4-5) solution that contains no EPA regulated metals.
Hazardous waste treatment of heavy metals is unnecessary and process rinse water is normally sewerable as non-hazardous effluent.
The working bath operates at 150deg F and does not cause a scale build-up on tanks and heaters, thereby minimizing process line maintenance.
On non-rusty surfaces, the Microlok AO coating process requires only five steps and 16 minutes process time: 1.
Clean and degrease the parts for 5 minutes in Safe Scrub ST biodegradable liquid cleaner at 150deg F.
2.
Rinse in clean water for 20 seconds.
3.
Apply Microlok AO coating by immersing parts in process bath for 10 minutes at 150deg F.
4.
Rinse thoroughly in clean water for 20 seconds.
5.
Seal in appropriate rust preventive, such as Sheath RB1 water displacing oil; or in DRI Touch Plus IRP3 non-tacky rust preventive.
Or force dry.
Or apply paint, and then cure as required.
Or apply stamping lubricant.
The Microlok AO finish is ideal for tooling and machine components, automotive parts such as tie-rods and ball joints, oil-field equipment - any part that does not require a black finish, but does require robust corrosion protection or anti-galling properties without a dimensional change.
The Microlok AO process is an easy and safe in-house coating system that can streamline part movement, reduce finished inventory and enhance ISO accountability.
Coating gives 50-year life in corrosive conditions
A special anti-corrosive surface treatment to coat storage drums containing low risk contaminated waste, is available for industrial applications under exposure to aggressive environments.
A special anti-corrosive surface treatment that was developed by Poeton Industries to coat storage drums containing low risk contaminated waste, is available for industrial and defence applications where long-term exposure to aggressive environments is a problem. The Apticote treatment consists of a sacrificial ’super-zinc’ base coating with a spray-applied, two-pack epoxy polymer finish. Poeton R and D manager John Archer says the coating was originally designed to provide a 50-year life for more than 5,000 BNFL storage drums, which were constructed of mild steel with inner and outer containers and a lid.
All surfaces were completely coated to resist any form of corrosive attack.
Explaining the long service life, he says corrosion can successfully attack a conventional ‘envelope’ coating such as paint through minute holes in its surface, while a ’sacrificial’ coatings such as zinc (galvanising) relies on progressive oxidation to protect the surface.
‘The reason the Apticote treatment is so durable is that it protects the sacrificial coating with an extremely tough corrosion resistant epoxy polymer that has already lasted ten years in our own atmospheric tests with absolutely no signs of deterioration!’ He says.
Poeton says the coating can be specified to prevent saltwater or atmospheric corrosion of components or structures in marine, defence and industrial applications.
High quality black oxide line is fast a finisher
New black oxide finishing line produces high quality finishes in under 20 minutes and provides better part inventory control, ISO compliance and faster turnaround of finished parts.
Faster turnaround of high quality finished parts to satisfy key customers is one of the important benefits of Birchwood Casey’s new in-house BC40 Tru Temp black oxide finishing system. Compared to sending parts to outside vendors for finishing, this in-house system produces high quality black finishes on iron and steel components in less than 20 minutes. No waiting.
The seven-tank line utilizes a patented two-step chemistry that produces a true black magnetite finish of.000020ý thickness, satin black in appearance and comparable to conventional hot oxide.
Because the Tru Temp process contains no EPA regulated chemicals, there is usually no need for waste treatment equipment.
In most sewer districts, the rinse waters are considered sewerable as non-hazardous effluent.
The initial capital investment, therefore, is only half that of other blackening process systems.
Additional process differences make the new Birchwood Casey BC40 system a major improvement over hot oxide.
The system operates at just 200degF compared to dangerous hot oxides that usually operate at 290degF.
Severe splattering and boil over hazards are not present.
The process is ideal for all dimensionally critical parts, including machine components, gears, and power drive components.
It meets military specification MIL-DTL-13924C Class 1, and AMS2485.
By keeping the finishing process in-house, part quality and inventory control is better managed, making ISO compliance easier.
Completely engineered design and ready for easy installation, the BC40 Tru Temp system utilizes seven individual tanks (16 x 24 x 24in deep) with a total footprint of 3 feet x 15ft.
Tanks are ruggedly constructed of either 10 gauge welded steel (epoxy painted) or 1/2in welded polypropylene and are supplied with all needed heaters and plumbing connections.
Fingertip controls manage manual powder coating
Manual powder coating system provides fingertip controls on its air gun that instantly activate a wide range of options while a 12-stage high voltage cascade offers high transfer efficiency.
The new Mach-Jet manual powder coating system from SAMES has been designed to outperform its competitors in virtually every respect. Fingertip controls on its electrostatic spray gun instantly activate an unmatched range of options. Twelve, pre-set powder flow adjustments are possible allowing even greater transfer efficiency, and believed to be the best currently available.
Mach-Jet is controlled completely electronically making it immune to the variability of pneumatic operation.
It is also one of the most balanced and lightweight systems on the market -660 grams - and despite all these credentials, it is also eminently affordable.
The mobile Mach-Jet will specifically appeal to companies wishing to optimise their powder coating application.
The main focus of the system’s flexibility is in its gun that gives single-handed control of four pre-selected spray settings and up to 12 levels of powder flow.
The operator can instantly switch between high Volt/micro Amp settings for fan spray, round spray, re-coating and metallic powder.
The setting selected is illuminated on the gun’s display as an easy-to-read icon.
This level of capability is not available on any other system.
This is not a totally airless system and is completely plc-controlled; a feature unique to Mach-Jet.
Other features that make the gun so easy and effortless to use are a hose swivel - which also prevents kinking - and a choice of two sizes of soft handgrip to accord with the operator’s hand size.
The system’s powder pump actively aerates the powder as it delivered to the gun, ensuring consistent and reliable flow.
The pump also features a new quick release hose coupling that allows fast colour change and cleaning.
Plugs and hoses are colour-coded for easy assembly.
To ensure that the optimum electrostatic charge is selected to suit the part and the powder, all the settings are programmed and adjusted via SAMES’ new, compact CRN 457 controller.
This is an intuitive system that is designed for simple and speedy, icon-driven programming.
This controller is integrated into the front of the cart and mounted on an incline to give the operator good visibility of the display.
The streamlined cart is manufactured completely from heavy duty engineered resin.
This makes it easy to manoeuvre and to clean.
It is also designed so that all system elements have a secure location and to provide additional storage for parts, nozzles etc Fitted as standard to the compressed mains air input connector is an air filter to remove any moisture.
Two versions of Mach-Jet are currently available - with vibrating table for box feeding or with 36-litre fluidised bed for hopper feed.
A pressurised powder hopper version with vibration is also scheduled for release during the summer.
This has been designed for pumping powder or heavy powders over greater distances then normal requirements.
An increase in powder output is also another benefit from this optional accessory.
Coating solves stick label printing problem
Coating specially designed for print and packaging applications involving adhesives has helped a label printing specialist solve a sticky production problem with a self-adhesive paper.
A new Apticote coating from Poeton Industries has helped label printing specialist, Norprint, solve a sticky production problem with a self-adhesive paper. Norprint Labelling Systems is one of Europe’s largest independent labelling companies with a capacity of 6.7 billion tickets, tags and labels every year. The company operates thirty presses including digital, rotary, flexo, letterpress and custom designed machines.
Several of the label presses operate a re-lam and de-lam process that peels the backing paper from a self-adhesive stock, allowing the machine to print onto the adhesive.
It then joins the two substrates together again.
The stock can stick to the rollers when the machine is running, and in order to minimise the problem, Norprint had been covering the rollers with a layer of silicone paper.
‘The search for a solution took us to the Internet, where we found the Poeton website,’ explains Norprint production manager, Malcolm Keightley.
‘We then phoned Poeton and discussed the problem with coating specialist Trevor Amos, who recommended Apticote 810SP - a coating that has been specially designed for print and packaging applications involving adhesives.
‘Poeton has been very helpful and the whole process has been easily managed by email, telephone and post.’ Initial indications at Norprint show that Apticote 810SP is helping to increase production and reduce costs and material wastage.
It is expected that Apticote 810SP will be used on six machines, possibly more - with other rollers due to be sent for coating.
Says Trevor Amos: ‘Following the original contact they sent us one roller for coating, which we returned for testing.
The self-adhesive stock ran without sticking and there was no drag from the material.
They were so impressed with the results after a one month trial that they sent another six rollers for coating, which are now fitted and operational on three presses.