This edition of the newsletter contains:

News features.
The Powder Coating Manual (Part 13)
Exhibitions and Conferences in and March and April 2003


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Lost: Space Shuttle Columbia IPC offers its condolences to the families of the seven astronauts lost in the February 1st tragic breakup of the Space Shuttle COLUMBIA.

Columbia's Thermal  Protection System: NASA FACTS
IPC

Thermal Materials

NASA selected four basic materials for the original. design used on Columbia, the first operational orbiter. The basic materials were Reinforced Carbon-Carbon (RCC), Low- and High-Temperature Reusable Surface Insulation tiles (LRSI and HRSI, respectively), and Felt Reusable Surface Insulation (FRSI) blankets. For the development flights, Columbia had more than 32,000 individual tiles covering the lower and upper surfaces, with FRSI covering the upper payload bay where peak temperatures were less than 600 degrees F.

Black or white tiles are used to protect the orbiter against temperatures between 1,200 and 2,500 degrees F.

Both white and black tiles are all made of the same base materials. These materials are manufactured in blocks (or billets) that are machined into the precise shape of the tile before application of the coating. The reaction cured glass (RCG) coatings are made from blended glass powders mixed with thickeners and pigments. The coatings are applied with conventional spray equipment, dried, and are then fired in a kiln at 2,200 degrees Fahrenheit for 90 minutes. The coatings are approximately 0.01 inch thick.

The tiles are bonded to the orbiter with a silicone adhesive. Silicones, unlike many adhesives, remain very flexible at low temperatures (experienced during the cold part of orbit) and retain good bond strength at the high temperatures experienced during reentry. The tiles are first bonded to a Strain Isolator Pad (SIP), a needled Nomex felt material, before bonding directly to the aluminum airframe (or graphite epoxy composite in the case of the OMS pods and payload bay doors). The purpose of the SIP is to allow the tiles to float very slightly to limit vibration-induced damage during the ascent to orbit and also to provide a means of compensating for the differences in thermal expansion between the tiles and the airframe. 

In January 1980, NASA announced a contract to develop a kit for astronauts to repair damaged heat shield tiles on the space shuttle. No such kit has been flown on a shuttle in recent memory, but the news item on  http://spaceflightnow.com/shuttle/sts107/030221tpsrepair/  makes for interesting reading in light of Columbia's breakup. Further details on Columbia's Thermal Protection System are available on http://www-pao.ksc.nasa.gov/kscpao/nasafact/pdf/tps.pdf 
You can report debris or images to NASA at this phone number: 281-483-3388 or (936) 699-1032. Text reports and images should be e-mailed to: columbiaimages@nasa.gov  or nasamitimages@jsc.nasa.gov 


Feedback from IPC's virtual community 

It (silicone coating )could be considered to form sheets of the ceramizing rubber and glue them in case of necessity onto the spacecraft body. This might not be a long lasting solution, however it might help to enter atmosphere without severe damages.
Dr. Torsten Sixt
WACKER SILICONES 

Try Silicone high temperature coatings used in barbecues and engine exhausts.
Regards
Ajit Gupta
Rapid Coat

It would seem possible to come up with some simple coating sprayed or layered into gaps in tiles or on top of them with disturbing them. We have various vacuum processes on the ground.
W Ford

I've spent a lot of time cooling my heals in the lobbies of different Flight Centers and most of the people around me were hawking their products and services.  They were met with and their product/service was discussed.  If they could qualify to do business with the government, they were given specifications and bidding guidelines.  It's pretty much the only way to be considered by NASA and its contractors.
John Hall 

How to do business with NASA 

"GUIDANCE  FOR  THE PREPARATION AND  SUBMISSION  OF UNSOLICITED  PROPOSALS" are available on  http://ec.msfc.nasa.gov/hq/library/unSol-Prop.html 

Advertisement feature ELECTRO- MECHANICAL RECIPROCATOR XL-SERIES Mitsuba introduces the Electro-Mechanical Reciprocator XL-Series. The Electro-Mechanical Reciprocator manufactured by MITSUBA SYSTEMS, possesses the capability to vary the speed & stroke to suit the conveyor speed and the jig height. The reciprocator are electrically driven via AC geared motor, giving gentle and distinct motion. The advanced control system of the reciprocators is designed to control reciprocating speed, stroke length & multi speed operations, thus ensuring the best possible coating results. Each reciprocator can accommodate up to 8 automatic guns and can this be used even where high line speeds are employed. Salient Features : Increased Uniformity - Advanced digital control. Improved Finish - Smooth movement during traversing and change of direction. Quick Job Change - Pre-programmable preset points for automatic selection of stroke and speed. Maximum Reliability - Simplicity of design and operator friendly controls. Do feel free to contact us to know more about how automation can reduce your powder coating coat. To know more about MITSUBA products please visit www.powdergun.com  Or contact us at:  Mitsuba Systems, 34/H, Laxhmi Industrial Estate, New Link Road, Andheri (W), Mumbai - 400 053 Tel : 0091-22-26318633/26334735/56924151/52/53/54 Fax : 0091-22-26316565 Email : mitsuba@vsnl.com  Website : www.powdergun.com

Cost-Cutting Program at Akzo Nobel
[Insider News] February 18, 2003 Issue
Akzo Nobel reported fourth-quarter net income excluding one-time items of 176 million euros, or approximately $190 million, a 21% decline from the fourth quarter of 2001. Sales for the quarter were flat compared to the prior-year period, at 3.385 billion euros. For all of 2002, net income excluding one-time items was 892 million euros, a 4% decline from 2001. Sales for the year declined 1%, to  14.002 billion euros. For the company's Coatings segment, fourth- quarter operating income was 81 million euros (approximately $966 million), a 23% increase from the fourth quarter of 2001. Coatings sales for the quarter rose 3%, to 1.277 billion euros ($1.383 billion). For all of 2002, Coatings operating income was 465 million euros, a 9% increase from 2001. Coatings sales for the year rose 2%, to 5.521 billion euros. The company said earnings were  up "significantly" for decorative coatings due primarily to cost savings and higher margins. Strong results also were reported for the company's Marine and Protective Coatings business. Industrial- coatings earnings improved, "although in general the business climate remains weak, especially in Europe," the company said. Chairman of the Board of Management Cees Van Lede said the company's fourth- quarter results were adversely affected by higher pension costs, negative currency exchange rates and a weaker performance for the company's Pharma segment. Results for the Coatings and Chemicals segments, meanwhile, were "substantially improved." Van Lede said 2003 "will be a tough year," and said the company will accelerate an ongoing cost-cutting program. The company said it plans to cut its work force by an additional 2,000 employees by the end of this year, bringing the total reductions to 5,500 since a cost-cutting program was launched in 2001. Of the 5,500 total, 2,500 will be Coatings- segment employees.

Commenting on this, Mr. Ishwar S said in his email "From the available information Akzo's results were affected by the larger pension corrections and the slow down in our pharma business which is driven by patent protection. Coatings did well and the challenge this year is to manage in a mature market when raw material prices are rising everyday". When asked, "If the coating is doing well, what is the reason for reduction in work force". Mr. Ishwar replied," Improving productivity and the impact of RM price increase is forcing all companies to downsize. Also a lot of things earlier done in-house is now outsourced...."


Asian Paints: Best Small Company for India
(European Coatings Flash - February 24, 2003)
"Asiamoney", one of the leading finance magazine in Asia and a subsidiary of "Euromoney" has adjudged Asian Paints among the Best Small Company 2002 for India (small company implies companies with market capitalisation below USD 500 million (INR 24.250 billion)). Asiamoney's 11th Annual Best Managed Companies across countries in the Asia region is based on a poll that is faxed to nearly 3,000 fund managers, Chief Investment Officers and Head of Research at fund management firms, insurance companies and brokerage houses in the Asia Pacific Region (including Australia & Japan), Europe and North America. Based on the findings of the poll and internal research, the Best Small Company 2002 & Best Managed Company 2002 for each country is decided. Asian Paints has been rated as the Best Small Company -2002 in India. In recognition of the achievement, Asian Paints will be felicitated by the publication at an Awards dinner at the Ritz Carlton Millenia, Singapore on Thursday Feb 20 at 1900 hrs. Commenting on being awarded the recognition, Mr. Ashwin Dani, Vice Chairman & Managing Director mentioned: "We are delighted to be accorded this recognition from one of Asia's leading financial magazine".

Goodlass Nerolac plans to shut Mumbai unit
(European Coatings Flash - February 03, 2003)
Goodlass Nerolac Paints is planning to close down its manufacturing unit in the city of Mumbai on account of non viability of the plant. The board, by means of a circular resolution, have given their consent to seek the approval of concerned authorities for closure of the Lower Parel unit in the central suburb, the company informed the Bombay Stock Exchange on 24 Jan.


Paints and coatings: adding more colours.
http://coatings.de/pcnews.cfm    
The paint industry in India has been on a steady rise since post liberalisation with several factors like reduction in the excise duty from 40.5% to 16% and improvement in the automobile industry adding to the growth of the sector. The industry mainly comprises two segments - decorative segment, which includes enamels, distempers, emulsions, exterior finishes and wood finishes; and industrial segment, which includes automotive coatings, high performance coatings, powder coatings, coil coatings and marine coatings. The decorative segment holds 70% of the Rup 500 bn paints market. After a poor phase in 2000-2001, the segment has recovered with a slight increase in margins but with a low growth of about 3.5% during 1H 2002. However, the industrial segment, which accounts for 30% of the market, recorded a promising 8% growth during 1H 2002. The Rup 500 bn organised sector in the paints industry holds about 60% of the market with few players like Asian Paints, Goodlass Nerolac Paints, Berger Paints, ICI, Jenson & Nicholson and others. The un-organised sector, which holds the balance 40% of the market, has 2500 small-scale units. The global demand for paints and coatings is projected to increase by 3% to about 26 M tonnes in terms of volume and by 4.6% to $80 bn in terms of value by 2003. Continued expansion in North America, favourable demand in Canada and Mexico, and anticipated recovery in Asian markets of China, Thailand, and South Korea is likely to add on to the industry worldwide. Also, shift to emulsion-based latex paints from solvent-based oil paints in the decorative paints segment, REFormulation strategies in the industrial paints segment, better growth in agricultural and industrial sectors, improvement in overall economic growth, good performance from industries like construction and automobiles etc, and improvement in consumer income and buying capacity could result as crucial demand drivers of the industry. Indian paints industry, with a very low base per capita consumption of 450-500 gms, still holds a promise with increasing population and growing housing sector. 


Chemical Engineering World, Dec 2002, 37 (12), 84 () (in English) 

RELIUS LAUNCHES NEW SUPERSOLID WOOD STAIN
http://www.pra.org.uk/publications/newsofthemonth/nom-index.htm
Relius Coatings of Germany has launched its new SuperSolid Lasur wood stain, claimed to minimise the natural swelling and shrinking tendency of wood. This high solid thixotropic system, with half the conventional solvent content, requires only two rather than three coats, thus saving on material and application time. The UV-filter and absorber in its formulation gives it durable weather protection. The colourless, transparent coating is also available in a range of colours through the Relius Living Colours system. (Farbenkreis, Nov 2002 (11), 20-1)

NATURAL PAINT MARKET IN EUROPE AT 7M LITRES
http://www.pra.org.uk/publications/newsofthemonth/nom-index.htm
So called 'natural paints', derived from renewable and natural mineral raw materials, are estimated at 7M litres in Europe. They are totally free of solvents and VOCs. Nonetheless their growth has recently suffered - down by 3% in 2002 and estimated at zero in 2003. The major manufacturers - which enjoy an aggregate market share of 50% - are Auro, Biofa, Leinos and BioPin. Second tier players include Livos, Aglaia, Ecotec, Naturhaus and Kreidezeit. DIY customers are mostly supplied by specialised distributors. Apart from eco- stores, an increasing number of conventional chain stores stock such products today. (Fischer, H, The Coatings Agenda Europe 2003 (Vincentz Verlag, 2003), 92)

SUPER-BLACK COATING CREATED
http://www.pra.org.uk/publications/newsofthemonth/nom-index.htm
Researchers at the National Physical Laboratory (NPL) in Teddington, UK, have recently announced the creation of a super-black coating, which reflects 10 to 20 times less light than the black paint currently used to reduce unwanted reflections in optical instruments. the coating is made by first immersing the object for five house in a solution of nickel sulphate and sodium hypophosphite, then etching the surface with nitric acid. It is reported that a wide range of materials can be coated in this way, including metals and ceramics. (NewScientist.com, 5 Feb 2003)

DULUX LAUNCHES "MAGIC WHITE" PAINT
http://www.pra.org.uk/publications/newsofthemonth/nom-index.htm
Dulux has recently launched a "Magic White" paint, this is pink in colour when applied, but changes back to white 35-40 minutes after application. This allows users to see exactly where they have painted, and areas that they have missed, ensuring a perfect finish when painting white onto white. The new coating can be used on both walls and ceilings. (Dulux shows DIYers what they've been missing, DIY Week, 24 Jan 2003, p 11)

PPG Earns ISO 14001 Certification at All Coatings-Production Sites Worldwide
([Insider News] February 24, 2003 Issue)

PPG Industries Inc. said it has earned ISO 14001 certification,
reflecting the company's compliance with international standards for
environmental management and energy efficiency, at all PPG coatings-
manufacturing facilities worldwide.


DuPont: Net loss for 2002
European Coatings Flash - February 17, 2003

DuPont Co. reported for 2002 a net loss of USD 1.103 billion, including a USD 2.944 billion charge for the cumulative effect of an accounting change. Net income in 2001 was USD 4.339 billion, including a USD 3.866 billion gain on the sale of DuPont Pharmaceuticals. Sales for the year declined 3 %, to USD 24.0 billion. For the company's Coatings & Color Technologies segment operating income was USD 483 million, a 7% increase from the previous year. Segment sales rose 1%, to USD 5.0 billion, with the increase resulting from stronger automotive-finishes sales, the company said.

Ferro forecasts 4Q 2002 earnings growth and schedules 4Q 2002 earnings release and conference call.
http://coatings.de/pcnews.cfm  

Ferro Corp expects 4Q 2002 fully diluted earnings/share from continuing operations to be between $0.16 and $0.22 (diluted earnings/share of $0.12 in 4Q 2001). The earnings growth reflects higher volumes and cost savings associated with the integration of the dmc2 businesses, which were acquired in Sep 2001. Revenue from continuing operations is expected to increase nearly 5% for both the Coatings segment and the Performance Chemicals segment compared with 4Q 2001. The Performance Chemicals segment earnings are expected to be less than that in 4Q 2001 due to the higher raw material costs and lower production rates as the company continued its effort to lower net inventory levels. Ferro Corp is a major international producer of performance materials for industry, including coatings and performance chemicals. 


Ferro 4Q 2002 earnings forecast, 15 Jan 2003, (Ferro Corp, 1000, Lakeside Avenue, Cleveland, OH 44114-7000, USA, Tel: +1 216 641 8580, Website: http://www.ferro.com ) (in English) 


Novapro signs exclusive deal with Nordson Liquid
Coatings Magazine eNews - February 12, 2003
Novapro Equipment Ltd. (Brampton, Ont.) is now an exclusive Ontario representative for Nordson Liquid. The news follows an earlier agreement last November, which made Novapro a distributor for Nordson's powder division.



The UCB Group
BRUSSELS, January 31, 2003(press release) - The UCB Group is pleased to announce that its acquisition of Solutia's Resins, Additives and Adhesives activity has been closed today, following the clearing of the transaction by the relevant competition authorities. UCB is acquiring Solutia's Resins, Additives & Adhesives activity for 500 million USD, in addition to a USD 10 million exclusivity fee.

Solutia's Resins, Additives and Adhesives activities are a natural fit for UCB's Chemicals and Films businesses. By integrating all three activities into one new business, Surface Specialties, UCB will create a strong global player in resins for industrial and specialty coatings, graphic arts and adhesives, focused on environmentally friendly technologies. In 2002, this new combined business would have represented a total turnover of 1.5 billion EUR, with approximately 4,700 employees worldwide.

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