The Powder Coating Process

 Generally powder coating may be regarded as an environmentally favoured method of applying a finish particularly as it avoids the use of solvent-based paints avoids overspray wastage, and any unused powder may be adequately recycled and used anew.

Although powder coating was conceived as a method of acquit yourself metal, technology has evolved for that excuse that it is now a common substitute for ceramics, plastics and even wood.

Research shows that powder coating is the fastest growing coating medium and behind the environmental advantages coupled in the back its excellent accomplish properties, it is a trend that is likely to continue.

Types of powder coating

There are two main types of powder coatings; thermosets and thermoplastics

With thermosetting variations, as the powder bakes, it reacts as soon as chemicals in the powder polymer which increases molecular weight; improving the comport yourself properties.

Thermoplastic types don't fine-tune specifically nor have any new reactions, it understandably flows out into the unconditional coating.

Powder coating process

Stage 1 - Pre treatment

This is roughly preparing the component or allocation, and as any painting application, preparation is all important to achieve the best feasible finish.

It is valuable to cut off oils and lubricants and metal oxides and this is performed usually by a variety of chemical and mechanical events, dependent furthermore in the region of the material, size, and finish required.

The quantity stage chemical pre-treatments usually influence using phosphates or chromates in submersion or by spraying.

From an environmental viewpoint those offering phosphate preparations are my preferred out of the undistinguished as chromates can be toxic to the atmosphere.

Another method of preparation is sandblasting and shot-blasting, whereby blasting abrasives are used to meet the expense of surface texture and preparation for wood, plastic or glass.

Silicone carbide is times-lucky for grinding metals and plastic media blasting uses plastic abrasives that are throbbing to substrates such as aluminium.

Stage2 - The powder application

The most used method is electrostatic spraying via a spray can can gun.

The mean is grounded and the gun imparts a deferential electric lawsuit onto the powder which is with sprayed and accelerated toward the component by the powerful electrostatic deed.

The component is frustrated, and the powder melts into a uniform film, and cooled to form a hard coating. We sometimes heat the metal first and spray the powder onto the tender substrate. Preheating can in the by now to achieve a more uniform finish but can moreover make new problems, such as runs caused by excess powder.

Powder can along with be applied using specifically adapted electrostatic discs.

Another method, known as the Fluidised Bed method, involves heating the substrate and subsequently dipping it into an aerated, powder-filled bed.

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The powder sticks and melts to the indulgent dream, when supplementary heating required to finish curing the coating. This method is generally used after that the coating exceeds 300 micros.

Electrostatic Fluidised Bed Coating: Electrostatic fluidised bed application uses the same fluidising techniques as above but considering much less powder height above sea level in the bed. Electrostatic charging occurs in the bed for that defense that the powder becomes charged as the fluidising let breathe lifts it going on. Charged powder particles form a cloud of charged powder above the formless bed. When a beached part is passed through the charged cloud the particles will be attracted to its surface. The parts are not preheated.

Electrostatic Magnetic Brush (EMB) coating is a coating method for flat materials that applies powder coating taking into account roller technique.

Stage 3 - Curing

When thermoset powders are exposed to high increases in temperature, (usually via a convection or infrared cure oven), they begin to melt, flow out, and subsequently react to form a well ahead molecular weight polymer. This cure process, called provoked linking, requires a get your hands on degree of temperature for a sure length of time in order to achieve full cure and assert the full film properties for which the material was expected.

What are the disadvantages of Powder Coating

Very skinny coatings can produce an effect pinholes

Very frequent colour changes can be period consuming

Inside corners can have low film thickness

Can be tricky upon brilliant corners

Needs triumph to treaty uniformity of thickness

Colour matching and uniformity can be harder than later than liquid paints

What are the advantages of Powder Coating?

Environmentally simple - no solvents required

Cost-effective

Finishes are tough and supple making it harder to chip or suspension

Generally gives a 100% hermetic coating

Almost no waste produced

Massive range of colours and finishes

Rust pardon

Can be applied on summit of a broad range of thicknesses

Can fabricate thick coatings without running or sagging

Special effects are easily practiced

Fast turnaround period

Protection adjacent door to outdoor UV fading

Exceptional colour retention

Excellent electrical insulation capabilities

Resistant to most chemicals and solvents