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This text introduces you to one of the most environmentally friendly and economical technologies for surface coating, which permits the carrying out of a wide range of applications, easily and cleanly. Powder coating has been used since the early Sixties. Initially, its production and application were not without problems. Today, however, powder coating is an established and acknowledged process, because powder paints are:
- environmentally friendly
- energy saving
- safe to process
- very economical
The Principles of Powder Coating with the Best Powder Coating Starter Kit
The elementary idea behind electrostatic powder coating is based on the fact that parts with opposite electrical charges attract each other.
Therefore, most conducting, and thermally stable solids are suitable for
powder coating. Above all today, metal objects are electrostatically powder coated in an ever-increasing volume. The most usual examples are:
- Household appliances
- Office furniture
- Garden furniture
- Automobile accessories
- Fittings
- Wire goods
- Sections
- Cladding elements
Daily, everyone comes into contact with the results of this technology. The dry coating powder is filled into a powder hopper, fluidized, and conveyed
by means of compressed air to the spray gun. A low voltage of 10 V is converted in the powder gun to a high voltage, according to the cascade principle.
One or more electrodes on the front of the powder gun charge the powder to 60 – 100 kV when sprayed. An electric field is created between the powder gun and the grounded workpiece.
The Powder Coating Powder
The powder particles follow these field lines and remain adhered to the object due to its residual charge. The so-processed workpieces can then be conveyed either manually or automatically to the curing oven, where the organic powder is melted to a smooth film at 160 – 200° C (320 – 392° F) and then hardened.
Because of its chemical characteristics enamel powder requires much higher temperatures, namely 780 – 830° C (1436 – 1526° F). The coating thicknesses with organic powder for decorative purposes are approximately 30 – 80 mµ and for functional purposes 200 – 500 mµ. Enamel powder can be used in a coating thickness range between 80 – 200 mµ.
Epoxy/polyester powder: It is the most widely distributed powder with the biggest market share. It has very good chemical resistance and excellent mechanical characteristics. Its gloss durability and its color appearance
are, however, mediocre. Its fields of application are industrial equipment paneling, office furniture, machine tools, water heaters, radiators, and shelving. Epoxy powder:
This powder has good chemical and mechanical characteristics, but renders color and gloss only poorly. This if further diminished by the UV rays in daylight. It is used for the underfloor coating of automobiles, pipe coating, fittings of all types, in the food processing, and chemical industries. TGIC polyester powder: It has good chemical resistance and very good mechanical characteristics.
Its gloss and color durability are good. It is readily used for open-air furniture, farming machinery, air-conditioners, fence posts, and aluminum sections, and architectural paneling. Polyurethane powder: The powder has good mechanical and chemical characteristics. Gloss and color are very durable. Polyurethane powder is used for automobile wheels, paneling, playground equipment, and fluorescent building parts.
Acrylic powder: It is well known for its good mechanical and very good chemical characteristics and for its very good color, and gloss durability. Washing machines, oven parts, microwave ovens, refrigerators, and automobile bodies (clear coat) are coated with acrylic powder. Structured powder: Caution is required when normal and structured powders are used in the same plant.
The Coating Quality
Contamination can severely affect the coating quality if the cleaning of the plant is not carried out very carefully when changing powders. Metallic powder: Basically, there are two types of metallic powders. With the first,
the metal pigments are mixed together, and dry. This powder achieves
a very nice metallic effect, but a danger of segregation exists. This
powder is inclined to give difficulties when being recovered. With
the other metallic powders, the metal pigments are extruded in/
bonded.
With these powders, the metallic effect tends to be mediocre, but the powders do not have problems when being processed. Metallic powders must never be used with normal Corona powder guns, as this will lead to short-circuiting, without special metallic nozzles.
The ion-reducing accessory (SuperCorona®) is to be removed before using metallic powders. As a rule, working with Tribo systems is not recommended. Using the same metallic powders with different systems, different plant or also only with different nozzles give differing colour results!
Clear coat powder: Thin film powder: As long as the plant is set correctly and carefully monitored, thin film powder does not give any processing problems. The coating results to be achieved depend, as with no other powder, directly on the care taken by the operating personnel when using thin film powder. Cleanliness in processing and care with the continuous
monitoring of the plant parameters are a ‘must’ when using this powder.
The best known, but also the most demanding example is the clear
coat powder coating of the BMW car bodies. Clear coat powder is
technically not more difficult to process than other powder types,
but requires considerably cleaner conditions. Clear coat powder
can be processed, by all means, without the clean room concept
with no problems, when the personnel operate the plant with the
corresponding cleanliness.
Enamel powder: Enamel powder is due to its composition very abrasive and requires special coating equipment. After stoving at 780 – 830° C an enameled surface is present, which can be heated to a temperature
over 450° C (842° F), and which is color-fast and scratch-resistant.
Enamel has a limited color palette, but the surfaces are finished by
this means displaying outstanding mechanical and chemical characteristics. That is why powder enamel is enjoying an ever-increasing popularity. The favored applications of powder enamel lie wherever especially high requirements are placed on a surface for resistance, such as on cooker panels, kitchen equipment, bathtubs, or shower bases.