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Ask Joe Powder.
Exhibitions and Conferences in May and June 2010
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India Powder Coating
3, Lalaram Nagar, Indore, 452001 MP India
Phone 91 731 2492291
emails: firstname.lastname@example.org , email@example.com , firstname.lastname@example.org
Manufacturer of Powder for Coating Purpose
An ISO 9001 Company
B 49, STICE, MUSALGOAN , TAL. SINNER,
DIST. NASHIK (M.S.),TELE-FAX : 02551-240475
Mobile :09922 028787
E mail : email@example.com
It was interesting to meet Sandesh Mulgaonkar (Technical Manager EC) and Sharad Saxena (Sales Manager CED) from PPG Industrial Coatings. They told us about the Technical and Commercial aspects of the Electro Deposition Process and the future of ED process in India. An electrocoating system applies a charge to a metal part that is immersed in a coating bath. The process is highly automated and results in a high performing finish that delivers a uniform film build, colour consistency, high yield rates and applied cost efficiency, in an environmentally friendly finishing system.
PPG Industrial Coatings has earned a reputation for innovative, high-performance products and world-class service. Serving the world’s top manufacturers and supply chain partners with a wide range of leading technologies, PPG enables customers to achieve their industrial coatings goals.
|Zinc-Aluminium Flake Coating:|
Water reducible Non-Electrolytically
applied Zinc-Aluminium Flake Coating:
Contributed by Kalyan Dhakane and Digamber Dhake
Brief History about Zinc Flake coating Technology
Since 1970-1975 the Zinc flake coating system is available in comparison with electrolytic applied zinc with higher corrosion protection. In the beginning producers were using hex chromium as a co-formulator to enhance corrosion protection, now a day’s chromium free zinc flake coatings also available with organic and inorganic colour sealer top coats in the market. The combination of Zinc flake base and different organic or inorganic top coats gives superior properties and it is applied for almost every metal part in Industry with help of different application techniques like and advanced coating machineries.
What is Zinc Flake Technology?
Polymet™ Zinc Flake coatings were made by combination of Zinc and Aluminum flakes, electrically conductive Binder system with integrated lubricants for adjusting co-efficient of friction. The coating is conductive which helps to protect cathodically and aluminum flake helps to reduce of white oxidation buildup. The Polymet™ coatings are Non-Electrolytically applied by mechanical application techniques with combination of Organic or Inorganic top coat sealers.
Polymet™ coating offers high performance corrosion protection for bulk components. It is applied using a so-called dip-spinning process. The layer is made up of a base coat and a top coat. The inorganic base coat is made up of zinc and aluminium flakes. The zinc gives cathodic corrosion protection. What is more, the zinc and aluminium flakes produced in the dry film form a barrier to reduce the impact of corrosive media including oxygen, electrolytes, etc. thereby enhancing the life of the complete protective system.
Both organic and inorganic coating systems are available for the top coat, each offering excellent protection from mechanical and chemical impact. Protection against contact corrosion is enhanced and abrasion resistance is clearly increased. Integrated dry film lubricants help achieve defined friction coefficients.
When combined with other processes, the zinc flake system offers excellent protection against corrosion as well as resistance to chemicals and is clearly superior to comparable systems.
There are a number of components which are combined to produce a high performance protective coating. For specific applications, we are able to formulate a specific product that will achieve optimum performance. As can be seen, the wide variety of components gives a wide spectrum of possibilities to solve any coating requirement need. Each coating formulation will have a number of components which can be combined for optimum technical performance within the cost/price economic window.
Binders are the materials which hold the other protective coating components to one another and to the surface of the substrate.
Metallic Pigments provide sacrificial protection to the substrate; these are metals that are more reactive than the substrate. While many metallic pigments are used.
The flake pigments give a brighter appearance than the dusts, which give a flat matt appearance. Corrosion protection is generally similar, although flake pigments offer better corrosion protection.
Lubricants reduce the coefficient of friction of the coating, resulting in improved torque-tension relationships for threaded fastener assemblies and improved bulk processing of parts. The lubricating pigments are selected according to price-performance parameters.
Inhibitive Additives are added to protective coating formulations to enhance the performance of the metallic pigments by reducing their electrochemical activity. Typical inhibitive pigments which can be incorporated in protective coating formulations
What Coating thickness is applied?
Generally, the coating thickness ranges from 5-15 microns. The corrosion resistance can be achieved over 1000 hours by ASTM B117 in Salt Spray test; The results of corrosion depends up on the shape and geometry of the parts.
More about it in the next issue of the IPC e newsletter
|Ask Joe Powder (New)|
"Ask Joe Powder"
"Ask Joe Powder" is a question and answer column authored by Kevin Biller of the Powder Coating Research Group. Mr. Biller has over 30 years experience formulating and manufacturing powder coatings. He welcomes your questions regarding powder coating technology. Please write to: firstname.lastname@example.org
The Powder Coating Research Group
4419 Brookpark Road
Cleveland, OH 44134
Hi Mr. Joe Powder!!
I have a question, we have a Powder Process here in our facility, and we use a PPG Epoxy, and it doesn’t pass an accelerated exposure test. Question is, this kind of Powder does or doesn’t pass the QUV test?
Because we are having troubles with our customers.
Thanks for your time.
Buenos Dios Tito,
Thank you for the question, this is a good one. The QUV test simulates the exposure a coating will experience in a high intensity UV environment. The wavelengths are close but not identical to the sun. It is a decent comparative test for similar formulations. Epoxies will not last long in a QUV chamber without fading and chalking. Similarly a hybrid powder coating which also contains epoxy resin will not resist degradation in the QUV cabinet.
Powder coatings that have good to excellent QUV performance are based on the following chemistries: aliphatic polyurethanes, polyester TGIC, polyester HAA, acrylic and fluoropolymer. Pigmentation also has a strong influence on UV resistance. Mixed metal oxides have the best performance.
If you need more guidance please let me know.
Is there any truth to shot blast being able to “impregnate” oils in the surface of steel? I have a product that gets E-coated off site, and I want to shot blast the product versus hand cleaning, but my customer is concerned.
Your customer has reason to be concerned. Shot blasting can be a very good pretreatment process before powder coating or painting a metal surface. The issue develops if the shot blasting process is sloppy. It is imperative to have clean blasting media. If the blasting media gets contaminated, yes it will embed the surface with dirt and oil. The microscopically embedded contaminates will compromise the corrosion resistance of the finish.
This doesn't mean shot blasting can't be used as a pretreatment, it's just really important to keep the process and media extremely clean. In fact a good shot blast process is better than simple solvent cleaning because the blasting, when done correctly, provides better adhesion. This is because it creates a profile on microscopic peaks and valleys that allow the coating to 'bite" into.
Let me know if you have any other questions.
Dear Mr. Biller:
I hope you don't mind me troubling you with a question regarding the failure of the epoxy/polyester powder coat to the metal on the equipment in my office. I found your site while searching the internet for answers.
I am a dentist in Florida and am experiencing problems with the finish to my dental equipment. The equipment is 3 years old and the the paint is bubbling up and chipping off the delivery units which is that movable tray holder that the instruments sit on. I have never seen this before in the 25 years that I have been working in dental offices. The paint is covered with a protective plastic that is lightly adhesive and disposed of after each patient. The paint is wiped down with a hospital grade disinfectant wipe after every patient as well. We first starting noticing the bubbling and "corrosion" about 18 months of use.
I have had dental equipment that was over 40 years old, disinfectant with diluted bleach that never displayed this type of wear.
The manufacturer said they never experienced this phenomenon on any of their products. They used epoxy/polyester powdercoat. They insist the units were manufactured in the US according to FDA standards.
Can you think of any reason why this would happen? If you need photos I can email them to you. I sincerely appreciate any insight you can offer to this problem.
Thank you for your time and consideration,
Maria Zecca-Botwin, DMD
From what you describe there can be a couple problems that are responsible for the coating failure. Here are some of the possibilities:
1. Incorrect or poor quality powder coating - The applicator may have pulled the wrong product off the shelf (e.g. mistook one white powder for another) and applied it to the dental equipment. A standard polyester product would not have the chemical or solvent resistance that a hybrid would. A more remote possibility would be a lousy quality batch of powder coating as supplied by the powder manufacturer. This doesn't happen very often however.
2. Inadequately cured powder coating - The applicator may have applied the proper coating, but didn't bake it at high enough temperature or time to adequately harden or cure the coating. An undercured powder coating will have poor chemical resistance and could blister and lose adhesion.
3. Poorly cleaned and pretreated metal prior to powder application - This is highly probable. If the instrument parts weren't thoroughly cleaned and pretreated prior to applying powder coating, this could result in premature bubbling and adhesion failure. Adequate cleaning and pretreatment would consist of a minimum of 5 stages including an alkaline cleaner, intermediate rinses and the application of a phosphate solution. Without this the coating will not anchor to the metal substrate and will subsequently corrode and lose adhesion.
As for the FDA standards, these regulate the composition of the powder coating. Details are contained in the Code of Federal Register (CFR) 175.300. The purpose of this is to ensure nothing leaches out of the coating that could harm a human. It does not regulate the performance or durability of the coating.
Did the equipment manufacturer provide a warranty for the performance of the equipment? I would think they are responsible for the durability of the equipment including its finish. They should correct the problem or replace the equipment. It would then be up to them to pursue the powder coating applicator (if it is not them).
It would be helpful to send me pictures. I could then comment further on the mode of failure and its possible cause(s).
Please let me know how I can help you further.
Kevin Biller aka Joe Powder
Joe Powder has over 30 years experience in powder coating formulating, manufacturing and troubleshooting. If you have a question, please feel free to submit it to email@example.com
|Seminar Events Exhibitions|
May 04 - 06, 2010 Louisville, KY
Process Cleaning Expo (PCx)
May 04 - 06, 2010 Louisville, KY
Basics of Polyurethane Coatings
May 05 - 06, 2010 Ypsilanti, MI
PEI Technical Forum
May 10 - 14, 2010 Nashville, TN
Surface Finishing Academy Introduction to Anodizing Workshop
Dates: 11 May 2010 until 12 May 2010
Location: Chicago, IL
Cleveland Coatings Society 53rd Annual Sink or Swim Symposium
Dates: 18 May 2010 until 19 May 2010
Location: Akron, OH
Kushner Electroplating School
Dates: 18 May 2010 until 19 May 2010
Location: St. Louis, Mo.
Introduction to Anodizing Workshop
by AluConsult May 11 - 12, 2010 Chicago, IL
Introduction to Paint Formulation
May 17 - 21, 2010 Rolla, MO
Advanced Topics in Polymers and Coatings
May 18 - 20, 2010 Ypsilanti, MI
Spray Finishing Technology Workshops
May 19 - 21, 2010 Toldeo, OH
RadTech UV/EB Technology Conference 2010
Dates: 23 May 2010 until 26 May 2010
Location: Baltimore, MD
2010 May 25 - 27, 2010 West Springfield, MA
Two-day Powder Coating Workshop
May 25 - 26, 2010 St Louis, MO
Asia Pacific Coatings Show 2010
23. - 24.06.2010
The Coatings Group
India Powder Coating
3, Lalaram Nagar, Indore, 452001 MP India
Phone 91 731 2492291
Mobile +91 9826297112
Alternative email firstname.lastname@example.org email@example.com, firstname.lastname@example.org
While we have used our best efforts in collecting and preparing the information on this website and newsletter, we do not assume, any liability for any loss or damage caused by errors or omissions, whether such errors or omissions resulted from negligence, accident or other causes. The user may use their own discretion while using the information.