Powder coating

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Powder coating is a type of dry coating, which is applied as a free-flowing, dry powder. The main difference between a conventional liquid paint and a powder coating is that, the powder coating does not require a solvent to keep the binder and filler parts in a liquid suspension form. The coating is typically applied electrostatically and is then cured under heat to allow it to flow and form a "skin." The powder may be a thermoplastic or a thermoset polymer. It is usually used to create a hard finish that is tougher than conventional paint. Powder coating is mainly used for coating of metals, such as "white goods", aluminium extrusions, and automobile and motorcycle parts. Newer technologies allow other materials, such as MDF (medium-density fibreboard), to be powder coated using different methods.

1 Advantages and disadvantages of powder coating
2 Types of powder coatings
3 External links
4 See also

[edit] Advantages and disadvantages of powder coating

There are several advantages of powder coating over conventional liquid coatings:

Powder coatings emit zero or near zero volatile organic compounds (VOC).
Powder coatings can produce much thicker coatings than conventional liquid coatings without running or sagging.
Powder coating overspray can be recycled and thus it is possible to achieve nearly 100% utilization of the coating.
Powder coating production lines produce less hazardous waste than conventional liquid coatings.
Capital equipment and operating costs for a powder line are generally less than for conventional liquid lines.
Powder coated items generally have fewer appearance differences between horizontally coated surfaces and vertically coated surfaces than liquid coated items.
A wide range of specialty effects are easily accomplished using powder coatings that would be impossible to achieve with other coating processes.

While powder coatings have many advantages over other coating processes, there are limitations to the technology. While it is relatively easy to apply thick coatings which have smooth, texture free surfaces, it is not as easy to apply smooth thin films. As the film thickness is reduced, the film becomes more and more "orange peeled" in texture due to the particle size and TG (glass transition temperature)of the powder.

For optimum material handling and ease application, most powder coatings have a particle size in the range of 30 to 50 micrometres and a TG > 40 C. For such powder coatings, film build-ups of greater than 50 micrometres may be required to obtain an acceptably smooth film. The amount of texture or orange peel which is desirable or acceptable depends on the end product. Many manufacturers actually prefer to have a certain amount of orange peel since it helps to hide metal defects that have occurred during manufacture, and the resulting coating is less prone to show fingerprints.

There are very specialized operations where powder coatings of less than 30 micrometres or with a TG < 40 C are utilized in order to produce smooth thin films. One variation of the dry powder coating process, the Powder Slurry process, combines the advantages of powder coatings and liquid coatings by dispersing very fine powders of 1-5 micon particle size into water, which then allows very smooth, low film thickness coatings to be produced.

Powder coatings have a major advantage in that the overspray can be recycled. However, if multiple colors are being sprayed in a single spray booth, this may limit the ability to recycle the overspray.

[edit] Types of powder coatings

There are two main categories of powder coatings: thermosets and thermoplastics. The thermosetting variety incorporates a crosslinker into the formulation. When the powder is baked, it reacts with other chemical groups in the powder polymer and increases the molecular weight and improves the performance properties. The thermoplastic variety does not undergo any additional reactions during the baking process, but rather only flows out into the final coating.

The most common polymers used are polyester, polyester-epoxy (known as hybrid), straight epoxy (Fusion bonded epoxy)and acrylics.

Production:

The polymer granules are mixed with hardener, pigments and other powder ingredients in a mixer
The mixture is heated in an extruder
The extruded mixture is rolled flat, cooled and broken into small chips
The chips are milled to make a fine powder

The most common way of applying the powder coating to metal objects is to spray the powder using an electrostatic gun, or Corona gun. The gun imparts a negative electric charge on the powder, which is then sprayed towards the object, which is grounded. The object is then heated, and the powder melts into a uniform film, and is then cooled to form a hard coating. It is also common to heat the metal first and spray the powder onto the hot substrate. Preheating can help to achieve a more uniform finish but can also create other problems, such as runs caused by excess powder. See the article "Fusion Bonded Epoxy Coatings"

Another type of gun is called a Tribo gun, which charges the powder by (triboelectric) friction. In this case, the powder picks up a positive charge while rubbing along the wall of a Teflon tube inside the barrel of the gun. These charged powder particles then adhere to the grounded substrate. Using a Tribo gun requires a different formulation of powder than the more common Corona guns. Tribo guns are not subject to some of the problems associated with Corona guns, however, such as back ionization and the Faraday Cage Effect.

Powder has also been applied using specifically adapted electrostatic discs.

Another method of applying powder coating, called the Fluidized Bed method, is by heating the substrate and then dipping it into an aerated, powder-filled bed. The powder sticks and melts to the hot object. Further heating is usually required to finish curing the coating. This method is generally used when the desired thickness of coating is to exceed 300 micrometres. This is how most dishwasher racks are coated.