Forrest Paint

Powder Coating Program

1

PRETREATMENT
 What is Pretreatment?
2

Cleaning to remove contamination that could

interfere with adhesion
Chemical removal of organic soils
Mechanical removal of inorganic materials
Possibly conversion coating to enhance adhesion
& provide some corrosion protection

2
 Why Pretreatment?
3

To meet product quality goals for appearance &

performance
Paint adhesion
Corrosion protection
Acceptable product appearance

3
 Selection of Pretreatment Process
4

What is the substrate?

What is the condition of the substrate?
What soils are present?
What are the goals for the product?
Where will the product be used?
What does the customer expect from the coating?

4
 Soil Types
5

Inorganics
Rust
Heat scale
Particulate
Laser Scale
Organics
Petroleum oils and grease
Polymers
Soaps
 Laser Scale Formation - O2 Assist
6

Laser heats steel to oxidation temperature

Oxygen assist gas reacts exothermically with steel creating scale
Impossible to prevent formation of scale

6
 Why remove Laser Scale?
7

Scale is brittle & loosely attached to steel

Scale can be chipped from edge
Coating adhered to scale will break from edge
Scale is can be removed mechanically or with acid

7
 Mechanical Cleaning Options
8

Mechanical cleaning - Surface abrasion

Sanding

Grinding

Blasting

Removes organic & inorganic soils

Provides excellent anchor for coating
Does not provide any additional corrosion resistance

8
 Mechanical Cleaning
9

Removes organic & inorganic soils

Provides excellent anchor for coating
Does not provide any additional corrosion resistance

9
 Mechanical Cleaning
10

Abrasives (Grinding or Sanding)

Difficult with complex geometry
Usually manual - time consuming
Potential to remove excessive material
Can leave cut marks
Shot or Grit Blasting
Good for hot-rolled steel scale
Effective on rust & laser oxide
Creates good anchor pattern

10
Hand Grinding
11

11
Manual Pressure Blast
12

12
Automated Blast Cabinet
13

13
Automated In-line Wheel Blast
14
 Blast Cleaning Standards
15

Cleanliness SSPC Standard NACE Standard

White metal SSPC-SP 5 NACE No. 1

Near white metal SSPC-SP 10 NACE No. 2

Commercial SSPC-SP 6 NACE No. 3

Brush-off SSPC-SP 7 NACE No. 4

SSPC Steel Structures Painting Council

NACE National Association of Corrosion Engineers
15
 Mechanical Cleaning Standards
16

White metal, highly corrosive environments all visible rust, mill scale,
paint, foreign matter
Near white, harsh environments 95% removal of all visible residue
Commercial blast, non-corrosive environments two-thirds of all visible
residue is removed
Brush-off blast, long-term coating life is not required remove all but
tightly adherent scale

16
 Types of Blast Media
17

Sand, steel grit, aluminum oxide, stainless steel, etc.

Size & Shape - spherical or sharp
Hardness vs. friability
Initial cost vs. number of cycles
Cost per use

Keep the Blast Media Clean!

17
 Chemical Pretreatment Process
18

Cleaning alkaline, acidic, neutral

Water rinse city water, counter-flowed water, filtered water

Pretreatment conversion coating

Water rinse city water, filtered water

Post treatment (Seal Rinse)

Reverse Osmosis/De-ionized water (RO/DI)

18
 Chemical Cleaning
19

Remove all soils (organic/inorganic)

Wand spray, dip or in-line spray
Chemistries
Neutral Cleaners

Acidic Cleaners

Alkaline Cleaners

19
 Defining a Clean Surface
20

Laboratory Development
Alcohol drop test
P.A.T. cleanliness

Surface carbon

In Plant
Visual inspection

Water break free test

White towel test

White Towel Water-Break

Visual Inspection
Mechanical

20
 The Importance of Water Rinsing
21

Removal of residual chemicals & soils

Halt reaction of previous treatment stage
Ensure that no un-reacted material is carried into
next stage or out of the end of the washer

21
 Rinse Water Preferences
22

Well water
Recycled water
City water
Reverse osmosis
De-ionized

22
 Conversion Coatings
23

A Chemical Conversion Coating Process

Changes the nature of the surface
Physically promotes adhesion
Chemically promotes corrosion resistance
Iron, zinc, chrome or manganese phosphate
Newer Conversion Coatings (Transition Metal Technology)
Zirconium oxide (nano-scale technology)
Zirconium/Titanium Based
Zirconium/Vanadium Based
Polymeric Based
Combinations

23
Conversion Coating Helps Inhibit Corrosion
24
 Surface Preparation Chemistries
25

Steel
Aluminum
Zinc coated steel
Other non-ferrous metals
 Conversion Coatings Selection Chart
26

Coated Surfaces Coated and Uncoated Surfaces

New Non-
Iron Zinc Chrome Chrome
Conversion Chrome
Phosphate Phosphate Phosphate Oxide
Substrate Coatings Coatings

Iron/Steel X X X

Galvanized X X X X X X

Aluminum X X X X X X

Galvanneal X X X

Magnesium X X X X X
 Iron & Zinc Phosphates
27
Iron Zinc
Process Process
Single to multiple stages Multiple stages
Clean/phosphate in one Requires conditioning step
stage
Performance
Performance Good physical adhesion
Excellent physical adhesion Excellent corrosion
Good corrosion resistance resistance
 New Conversion Coatings
28
New Conversion Coating Solution~90% Efficient in the use of the bath

Soluble by-products
No Solid Waste
Coating
Me+2 + Reaction Bi-Products
Components

Conversion Coating

Metal Substrate
 New Conversion Coatings
29

Little or no heat
Very little or no phosphorous
Almost no sludge
Easier maintenance
Non-regulated materials
Excellent for multi-metal applications
 Environmental Protection Agency Discharge Limits
30

Metals: Federal 40 CFR 403 & 433

Zn: 1.48 mg/l
Ni: 2.38 mg/l

Phosphorus: Local Municipality Limits

Minnesota: 4 mg/l

Wisconsin: 1 mg/l

Toronto: 10 mg/l

Additional Sites Pending

 New Conversion Coatings
Preferred System Requirements
31

Stainless steel construction

Very clean water
Excellent cleaning
Excellent rinsing between stages
 Aluminum Conversion Coatings
32

Exclusively for Non-Ferrous Surfaces

Four Types of Conversion Coatings
Chrome Phosphate

Chromate

Chrome Oxide

Non-Chrome
 Aluminum Conversion Coatings
33

Amorphous Coating appearance

Coating weights range from 2.0 to 20 mg/ft2
All coatings contain some metal oxide
Aluminum, Chromium, Zirconium, Titanium, etc.
Primary Function Paint Adhesion
Secondary Function Corrosion Resistance
Bare Corrosion Resistance
 Aluminum Conversion Coatings
34

Spray, Immersion or Dry-In-Place (DIP)

Some processes require a Deoxidizing Step
Aluminum industries
Extrusions
Aviation
Automotive - Wheels and Components
Marine
Architectural
 Post Treatments (Seal Rinses)
35

Post Treatment Properties

Applicable with iron or zinc phosphate coatings
Prevent flash rust
Leave substrate in slight acidic condition
Enhance the phosphate coating
Water source/quality
 Types of Post Treatments
36

Reactive
Post treatments will react with the substrate and the coating
resulting in a passivation of the surface
Non-Reactive
Post Treatments will lay down a protective coating passivating
the surface. These typically are considered dry-in-place
 The Pretreatment Process
37

Planning and Managing the Process

Parts: size, configuration, materials of construction, and quantity
Handling: production requirements, equipment capacity, racking
(batch or conveyor), labor requirements
Environmental: effluent air emissions, safety, waste, and energy
Quality: prior to coating, post-coating, standards for both
Maintenance: ease of operation, repair, dependability
 Methods & Process
38

One step processes

Spray wand systems batch pretreatment
Typical Pretreatment Chemistry: Iron or Aluminum
Immersion systems batch pretreatment
Typical Pretreatment Chemistry: Iron or Zinc

Conveyorized Pretreatment Systems

Spray washers Typical: Iron, Zinc or Transitional
3-stage, 5-stage, 6-stage
Immersion washers Typical Chemistry: Zinc or Transitional
8-Stages and up
 The One-Step Pretreatment Process
39

Degreases & phosphates simultaneously

Operates at room temperature
Ferro-organic conversion coating chemistry
Treat steel, aluminum, galvanized & other metals
Safe environmental profile
Uses no water, not rinsed, creates no waste
Immersion for Batch

Flooding Type Spray

for In-line Systems
 Spray Wand Systems
40

Wand systems useful for:

o Larger, lower volume operations
o Lower investment
o Space limitations
The same principles apply as spray washers
 Spray Wand Systems
41

Stage When Used Comment

Foam or gelled products give extra
Heavily soiled parts (grease or
Clean dwell time
oxidation)
Clean from the bottom up
Rinse Required when cleaner used Rinse from the top down

Iron Phosphate Always Phosphatize from the bottom up

Rinse from the top down. Rinsing will

Rinse Highly recommended/ required improve performance of coating
system.
Adhesion/ corrosion resistance
promoters available. Flash rust
Seal Occasionally used
inhibitors used for metallurgy highly
susceptible to corrosion.
Spray Wand Applications
42
 Batch Pretreatment
Immersion Systems
43

Advantages
Simple to maintain with few mechanical parts
Relatively low capital cost needed (batch)
Prolonged chemical contact time
Full wetting of complex shapes
 Batch Pretreatment
Immersion Systems
44

Disadvantages
Less mechanical/physical force to remove soils
Increased process control: contact time, chemical
solution temperature, & concentrations
More suited to batch processing vs. continuous
production flows unless conveyorized

44
Conveyorized Systems
45
 Conveyorized Pretreatment
Spray Washers
46

Advantages
Efficient
high volume throughput
cleaning and conversion coating
Shortened process times
Reduced temperatures
Chemical concentrations can be minimized

46
 Three-Stage Washer
47

Stage 1 D Stage 2 D
Stage 3
R R
Clean & A Rinse A
I I Post
Phosphate Treatment
N N
(Seal Rinse)
 Five-Stage Washer
48

Stage 1 D Stage 2 D D D
Stage 3 Stage 4 Stage 5
R R R R
A A A A
Clean I Rinse I Phosphate I Rinse I Post
N N N N Treatment
 Cost Drivers
49

Targeted longevity of finished part

Surface area processed
Washer design
Drain zones/spray patterns/etc.

Part profile/drag-out
Part condition & soils
 Cleaner Process Cost Savings
50

Prolong the Cleaner Bath Life

Filtration for solids removal

Oil removal

Counter-flow Alkaline Water Rinse stages

Multiple Cleaner stages

Spray followed by Immersion
Frequent dumping of small spray and rebuild with immersion stage
 Water Rinsing Cost Savings
51

How to control water usage

Overflow of Rinses Counterflow multiple rinse stages
Dump Frequency
Recycle

Improves Performance
use as rinse make-up water through spray nozzles
use as cleaner make-up water

use as pre-clean spray

 Materials of Construction
52

Pretreatment chemistry is the prime consideration in

determining the materials of construction.
Mild steel
Stainless steel
Composite
Plastic
 General Pretreatment Problems
53

Poor Adhesion
Blisters
Surface Defects
Dusty Coatings

Incomplete Coatings

Powder Coating Defects

Poor Corrosion Resistance

 Maintenance & Control for Quality
54

General Chemistry Conditions

Maintain all bath parameters within the Control Plan
General Equipment Conditions
Maintain good working nozzles

Ensure adequate pump pressure and solution delivery

Maintain all filtration on cleaning and pretreatment stages

Maintain all heating equipment

 Maintenance & Control for Quality
55

General Conditions to avoid:

Inter-stage drying

Poor water quality

Poor work piece quality

Clogged or faulty nozzles or plumbing

 Forrest Paint
Powder Coating Program
1

POWDER APPLICATION

RODGER TALBERT
TALBERT CONSULTING
 Powder Application System
Application Gun
Control Unit

Grounded Part to Coat

Powder Pump

Feed Hopper

Compressed
Air Supply
Fluidizing Plate

2
 Application System Components
3

Delivery System
Feed hopper or box
Pump
Hose
Gun barrel & nozzle
Pneumatic controls

Charging System
Generator
Cable
Electrode
Voltage & micro-amp control
 Powder Delivery

Clean, dry air supply

Optimum flow rate & pattern
Uniform fluidization
Clean, well maintained delivery path

4
 Powder Fluidization
5
Powder Pump
Fan
Final Filter Hopper Vent

Pick-up Tube

Fluidizing Plate

Compressed Air Inlet

5
 Fluidization
6

Keeps powder suspended for

easy delivery
Prevents powder
agglomeration
Keeps powder moving for
consistent feed
Conditions powder and
prevents powder separation
Helps keep powder dry

6
Excess Fluidization

Excessive Fluidization
Surging - inconsistent spray

Powder escaping from the hopper

Voids in spray pattern

Increased wear on parts

7
Insufficient Fluidization

Spray pulsing
Higher pump pressure settings
required
Increased wear on parts

8
Proper Fluidization
9
Contaminated or Damaged Fluid Plate

Primary Cause of Poor Fluidization

Oil Scratched
10
 Box Feed Unit

For smaller batches

More frequent color change
Faster color change

11
 Vibratory Box Feeder
12

Vibration combined with fluidization air at the

suction ring at the base of the pick up tube.

12
 Venturi Powder Pump Operation
13

The powder pump is designed to deliver powder to the applicator

Pump

Feed/Delivery Air

13
Dense Phase Transport Pump

Powder drawn into pump via vacuum

Powder pushed out to the gun using
very little air
Powder flow rate controlled by cycle rate
Powder/air ratio doesnt change with
powder output
Uses smaller ID powder hose

14
Stirrer or Gravity Hopper

15
Bulk Feed Systems
16
 Powder Feed Hose

Polyethylene
Conductive polyethylene
EVA plasticized
PVC
Isoprene rubber
Natural gum rubber
Polyurethane
Polyester
And others..

17
 Corona Charging Process

Powder particles acquire charge while

traveling from the gun to the part through
the electric field of corona discharge
18
 Factors Affecting Corona Charging

o Gun-to-part distance
Charging Time - o Powder velocity
o Electrode/Nozzle configuration

o Electrostatic parameters (kV; mA)

Field Strength - o Gun-to-part distance
o Electrode/Nozzle configuration

Particle Size -
o Powder particles; larger particles
hold more cumulative charge

19
 Application Goals

Complete coverage as required

Film thickness control
Proper appearance properties
Efficiency & cost control
Maximum throughput
Limited rejects
Limited waste

20
 Control Factors for Deposition

Powder material charging characteristics, consistent grind

size, ratio of virgin powder & recycled powder
Voltage & micro-amps optimum numbers based on powder
& part
Gun position consistent vertical position & correct gun-to-
target distance; repeatable patterns & technicque
Flow rate enough powder to cover in the spray zone at the
desired film thickness; avoid excess flow
Spray pattern match pattern to target
Spray technique consistent, steady, smooth

21
 Powder Particle Size Distribution

A blend of particles is necessary for a level film

Too much coarse material will reduce efficiency
& lead to a rougher film
Too much fine material will radically reduce
efficiency, cause more rejects, limit Faraday
cage penetration & require higher flow rates
Distribution changes during recovery

Good Blend Too Coarse Too Fine

22
 Powder Particle Size Bell Curve

Finer particles (< 20 micron): do not cover as well

High charge-to-mass ratio but low cumulative charge
Requires higher flow to cover

Coarse particles (> 85 micron): more orange peel

Strong cumulative charge

Do not flow out as well

% of Total
Best TE
Range

Fine Median Coarse

23
 Powder Material Cartridge Recovery
24
14

12

10

8
Differential
Volume, % 6

0
210 125 75 45 25 15 10 5 3 2 1
Microns

Virgin Reclaim
 Powder Material Cyclone Recovery
25
14

12

10
8
Differential
Volume, % 6

0
210 125 75 45 25 15 10 5 3 2 1
Microns
Virgin Reclaim
Particle Size & Film Build

Insufficient
Q Attraction

Strong Mirror
Q Image Attraction

26
 Ohms Law

50
V is the potential difference
8"
measured across the conductor in
units of volts
50

3"

I is the current through the

conductor in units of micro-amps
R is the resistance of the
conductor in units of ohms

27
 Target Distance (Electrostatics)

kV 10
Target distance affects the resistance as
the gun gets closer to the grounded
100 6 surface
Gun Voltage

85
3 Optimizing the application requires a
balance of the load & control the free ions
63
in the process

45 Current draw has to be at an optimum level

mA
20 50 75 160
Gun Current
28
 Current Limiting
29
Conventional Current Limited
10 10
kV kV
100 6 100
Gun Voltage

Gun Voltage
85
3 85
63
58
3
45
40

mA mA
20 50 75 160 20
Gun Current Gun Current
Faraday Cage Effect
30

Electrical resistance associated

with inside corners or recesses
 Faraday Cage Effect

Powder pattern
Charge
Air flow

31
 Faraday Cage (Aerodynamics)

Proper flow rate & position to get

powder into a recessed area, where
charged powder can attract to the walls
& velocity does not disturb pattern

32
 Forces that affect a Charged Particle
33
Particle is attracted to part because of electrostatic charge
Attraction is influenced by aerodynamic interference

Electric Force
Air Resistance

Weight
Powder particles are easily influenced by competing airflow.
Charge must be strong & velocity in spray area must be low
for high transfer efficiency
 Back Ionization

Back ionization occurs when too much charge

accumulates on the powder coating layer

34
 Counter-Electrode
35

Corona Gun with Ion Collector

Ion collector draws excess free ions back to an

alternative ground reference, delaying the onset
of back ionization
35
 Gun Position
36

Too Far Away

Correct Distance
Too Close
 Gun Position
37

Uniform spacing
Uniform, proper
target distance
Right number of
guns
Moderate flow
rates
 Flow Rate & Pattern Control

Consistent and even delivery of powder, properly

maintained nozzles, smooth, soft powder flow,
better finish results

38
 Powder Flow Rate Control

Powder material
Avoid excess fines

Clean, dry compressed air

Test air; +38 dew point or lower, <0.1 PPM of oil, no
particulate greater than 0.3
Fluidization
Uniform movement like water at a low boil

Clean, well maintained delivery path

No blockage or worn parts

Correct volume & ratio of air supply

Good pattern control & moderate flow rate

39
 Factors that affect Powder Delivery Rate
40

Compressed air supply

Hopper fluidization

Powder hose lengths

Wear on replacement pump parts

Powder particle size & specific gravity

Temperature & humidity

Spray Pattern Control

41
 Flat Spray Patterns

6" 10" 12"

6 mm 4 mm 2 mm
Flat-Spray Nozzles

42
 Conical Deflector Spray Patterns

4" 10" 24"

43
Irregular Fan Spray Pattern

Excessive wear of nozzle

and/or impact fusion
Incorrect controller
settings
Causes inconsistent film
deposition

44
Irregular Conical Spray Pattern

Poor pneumatic settings

can cause uneven
patterns
Deflector may be
impacted with powder

45
 Spray Technique

Uniform Application

Good practice leads to good parts

46
 Powder Application Technique

More is not necessarily better

Powder flow rate
Gun voltage
Gun current
Booth airflow velocity
Hose length

47
 Powder Application Technique

Flow rate
o A small amount of powder
with high efficiency
o No flooding with powder; concentrate on
gun settings

Application efficiency:
o Optimize gun-to-part distance & gun
current; 4 10 for manual, 8-12" for
automatic
o Control powder spray velocity
near the part surface
o Proper nozzle selection
o Smooth, consistent spray pattern

48
 Manual Gun Controllers

Total air volume

Powder volume
Powder velocity
Charging settings
49
 Automatic Gun Controllers

Automated control
Recipes
Flow rates
Standard settings
Consistency

50
 Controls Capabilities
51
Part Recipe Capable
Reciprocators
o Stroke and Speed

o Line Speed Adjustments

Gun Controls
o Voltage and Current

o Powder Output

System Protection
System Functions
System Monitoring
 PLC System Controls

Color Change Sequences

Booth Diagnostics
Gun Triggering
In/Out Positioning
Part Style Input

52
Manual Fast Color Change Systems

53
Automated Fast Color Change

54
Powder Feed Center

55
 Application Efficiency

Powder material management

Test powders for application characteristics; lower
price per pound may be the most expensive powder
Understand Specific Gravity
Maintain particle size

Gun controls
Optimum flow rate & charging set-up

Spray technique
Consistent, smooth, accurate (training helps)

Racking
Proper density, good ground, good access to all
surfaces

56
Application Efficiency Optimization
57
 Line Density
58

Good line density

Poor line density
 Fixed Guns

Fixed guns can be useful for a specific target

59
 Gun Movers and Positioning Devices

Fixed guns
Fixed guns with motion
Rotary oscillator
Oscillator
Reciprocator
Multi-axis
Robots

60
 Application Problems
61

Faraday areas
Light coat
Heavy coat
Inconsistent film
Hook scars
 Poor Charging & Coverage
62

Check ground from conveyor rail (or rub bar when used) through
hanger to part. All contact areas must be free of powder buildup,
heavy grease and other insulating materials
Check ground resistance value
Use Meg-Ohm meter (500 V)
Resistance < 1 Meg-Ohm
(per NFPA)
If the resistance is more
than 500 ohms, clean the
conveyor hooks.
 Poor Ground = More Rejects
Hook maintenance & design
o Keep rack contacts clean
o Self-masking contact point

Good Ground Good Ground

If the resistance is more than

500 ohms, clean the conveyor
hooks.

Poor Ground Poor Ground 63

 Flow Rate & Ground

Poor Ground & High Flow Rate Good Ground & Correct Flow Rate

64
 Too Much Powder Being Sprayed
65

Poor application efficiency

Excessive material waste
Powder material deterioration
Excessive wear
Increased maintenance
Potential safety issues
Color change issues
Blockage in Powder Path
66
 Back-ionization
67

Orange
Peel Star

Limit Current
Increase distance from part
Less film
Pin-hole Lower voltage for recoats
Good ground
 Forrest Paint
Powder Coating Program
1

P O WDE R C O A TI N G B O O THS &

R EC O V ER Y

RODGER TALBERT
TALBERT CONSULTING
 Powder Booths & Recovery Systems
2

A powder booth is designed to contain the spray

process
A powder recovery system provides airflow into the
booth to keep the powder inside & capture it for
reuse or disposal
 Powder Booths & Recovery Systems
3

Powder Booths Should:

Contain powder & process
Provide a safe operating environment
Recover over-sprayed powder
Enhance application efficiency
 Booth Design Features
4

Airflow
Lighting
Space
Cleaning/color change
Application efficiency
Materials of construction
 Booth Airflow
5

Containment of powder negative airflow is created

inside the booth to capture overspray
Efficient application excess velocity interferes with
application
 Powder Booth Sizing
6

Total Air Flow Required to Contain Powder in Booth =

Total Openings Area x Face Velocity Through Openings

End Opening
8'H x 10'W = 80 sq. ft.

80 sq./ft. x 80 fpm face velocity = 6,400 cfm

100 fpm face velocity = 8,000 cfm
120 fpm face velocity = 9,600 cfm
 Sizing, Space, Visibility
7

Big enough to avoid high velocity in spray zone

Space & time to reach all surfaces of the parts
Adequate room for manual touch-up
Good lighting to avoid shadows
 Booth Design
8
Part hook length 27 from hook point

Normal part clearance of 6 on all sides

Smooth rigid internal structure 27

Visibility & lighting

6
 Cleaning & Color Change
9

Equipment options that fit the operation

Duplicate equipment
Training of operators
Planned activity
 Color Change Options
10

Cyclone System
Cartridge System

Batch System
 Evaluation of Collection Options
11

Number of colors
Frequency of color change
Powder cost
Labor cost
Cost of down time
Capital investment
Space

11
 Application Efficiency

Enough guns to avoid excess flow rates

Good, consistent spacing
Booth cabin large enough to provide a good spray
zone; avoid spraying outside of booth openings &
conveyor slot

12
 Booth Construction

Stainless Steel
Durable, rugged construction
Attracts more powder, more to clean

13
 Powder Coated Walls

Bright background
Low powder attraction to walls

14
 Thermoplastic Walls

Thermoplastics (polypropylene, clear plastic)

Allows some light into booth
Attracts less powder, easier to clean

15
 PVC & Composite Walls
16

Light background for good visibility inside booth

Attracts even less powder, easiest to clean
 Types of Powder Booths
17

Lab booths
Batch booths
Walk-in batch booths
Booths for conveyor systems manual &
automatic
 Batch Booth Design
18

Considerations:
Production volume

Part size

o Clearance
o Access to surfaces
 Batch Booth Design
19
Material handling options
o Hanger
o Carts
o Rail system
Grounding
Operator clearance (3 guide)
Removal of powder
Reclaim vs. spray to waste
Batch System
20
 Recovery Systems
21

Powder
Cartridge Cyclone
Booth

Cartridge Collector Systems Cyclone System

Cartridge filter module is attached Cyclone used as a separator with
to the side or bottom of the booth. a cartridge module secondary filter.
Cartridge Recovery Systems
22
 Cartridge Booth Process
Work Piece Collector with Color Module
Spray Booth

Final Filter

Spray Gun Powder

Supply
Fan

Powder Spray Rotary Sieve

Gun
Cartridge Filter

Drum Unloader

Transfer Pump
Feed Hopper

23
 Cartridge Collection Systems
24

Closed collection system

Collector per reclaim color
Ideally suited to one color,
limited number of colors or
spray-to-waste or
Color change considerations:
Time
Collectors & ancillary equipment
Capital investment
Construction design
Spray-to-waste vs. reclaim
 Cartridge System Strengths
25
Cartridge Booth
Single colors
High reclaim efficiency

Multiple colors
Multiple booths
Time or gap required
Spray-to-waste
Fast color change 20 to 60 seconds
Recovery
Low color change frequency
Break even point 1-3 colors
 Cyclone Recovery System
26

Reclaim system is connected by ductwork Cyclone is a separator

Cartridge module
is a secondary filter
Cyclone Recovery System Process Flow
27
 Cyclone Technology
28

Ideally suited for multi-color applications

One capital investment, all colors
Automation for color change
Gun cleaning, inside & out

Pump & hose purge

Powder center for delivery

Minimize powder in cycle

 Cyclone System Strengths
29

One booth for any number of colors

Can be fitted for rapid color change of reclaim colors
 The Impact of Color Change
30

Manual or automatic
Reclaim or spray-to-waste
Equipment options
Number of people
Number of booths
Frequency of color change
Uptime in a single color
 Factors to Reduce Color Change Time
31

Increase application efficiency

Line density
Application process
Minimize amount of powder-in-process
Recovery & booth design
Housekeeping
Feed center automation
Color change process
Well-coordinated teamwork
Precise procedures
Production schedule
Light/dark color designated equipment
Spray to waste short runs
 Booth Design Optimization
32

Reduce powder in process

Continually clean floor
Structure minimizes powder

Seal booth during cleaning

Close doors one end of booth

Increase containment

Simplify blow down

Smooth interior
Easy access
 Shortening Color Change Time
33

Increase application efficiency Means less powder in the

booth to clean up!
Powder Feed Center Automation
34
 Powder Material Management
35

Control Virgin/Reclaim
Use reclaim as it is generated (no stockpile)
Add virgin consistently

Stable balance critical to effect powders

Metallic, veins and wrinkles good examples

Low Specific Gravity Powder
Depending on effect, fillers & additives impact
color change negatively
High specific gravity can mean high additive content

Lighter colors often need more pigment content

Minimize fines in application

 Operating Environment
36

Environmental room is recommended

Heat & humidity maintained
Fluidization
Powder flow & material handling
Application charging
Faraday application
Impact fusion
First pass transfer efficiency

Quality application needs a quality environment

o Control parameters
o Temperature 50 - 80 F
o Humidity 40 60% RH
o Dirt and contaminants minimized
 Air Dryers
37

Refrigerated Air Dryer 35 F

Regenerative Air Dryer -20 F

 Reclaim System Cartridge Troubleshooting
38

Powder escaping from booth

openings
Clogged cartridge filters
Compressed air system
Cross drafts interfering
with exhaust fan draw
Guns spraying towards
entrance/exit vestibules
Reversed fan rotation
Air leaks around color module
Powder gun output exceeds
booth containment capacity
Final filter clogged
 Reclaim System Cyclone Troubleshooting
39

Powder escaping from booth openings

Clogged cartridge filters

Compressed air quality

Cross drafts interfering

with exhaust fan draw
Guns spraying towards
entrance/exit vestibules
Reversed fan rotation

Air leaks around cyclone

Excessive gun outputs

Final Filter clogged

 Booth Design Features
40

Materials of construction
Application considerations
Cabin size
Cleanability
Visibility
Access
 Forrest Paint
Powder Coating Program
1

DRYING & CURING

RODGER TALBERT
TALBERT CONSULTING
 Drying

2
Angle Parts for Drainage
3

No angle traps water!

Angle allows water to drain.

 Blow-off
4

Remove excess water that has not drained or is

trapped in pools
High velocity air can blow water off the surface
Methods
Compressed air high pressure in isolated area,
high cost and labor intensive
High pressure blower high pressure in broad area,
lower cost and less labor intensive
Combination may be necessary to get rid of all
water
Manual Compressed Air Blow-off
5
High Velocity Blow-off
6
 Dry-off Ovens
7

Factors that contribute to drying

Time 5 to 10 minutes is typical
Temperature of 250400F - use the lowest possible
effective temperature
Air movement higher air velocity assists drying at
lower cost than heat
 Convection Dry-off Ovens
8

Convection ovens use re-circulated air to heat to the part

& create air movement
Air velocity provides faster heat bring-up time and more
effective drying
 Part Cool-Down
9

Powder will melt on the part surface during

application if the temperature is too high
Recommended part temperature in the booth
should normally be less than 120F
 Cooling

Time
Cycle enough conveyor to allow parts to cool in ambient air
Forced cooling
Install fans or a cooling tunnel to reduce temperature in less
time

10
 Cooling Tunnel
11

Intake Air To Atmosphere Or To Plant

 Curing the Powder
12

Thermoset materials require thermal energy to cross-link

material and provide the visual and functional properties
to the powder
Cure ovens are used for application of thermal energy
 Curing & Oven Cycle Time
13

Two conditions needed to achieve proper cure of a

powder coating
The part must reach the recommended cure temperature
The part must dwell at cure temperature for the
recommended time
Within limits, shorter oven cycle times are
possible if the temperature is increased
 Cure Cycle
14

Cure depends on time and temperature

More time can be used to reduce temperature
More temperature can be used to reduce time
Standard Cure Schedule
Minutes Temperature
20 350F
15 375F
10 400F
8 425F
 Curing & Oven Time
15

Temperature for cure is Peak Metal Temperature

Total cycle time has to include bring-up time
 Types of Cure Ovens
16

Convection Thermal
energy delivered by air
circulation

Infrared - Thermal energy

delivered in electromagnetic
wave-lengths
 Selection Considerations
17

Convection alone for standard products & line speeds

IR alone for some one-part lines
Combination ovens for flexible cure or increased production
Minimize overall oven size
High efficiency IR booster to quickly elevate part
temperature
Convection oven for the most even cure of different metal
gauges
 Convection Ovens
18

Very flexible for different cure cycles & parts

More uniform cure
Industry standard for many years
Larger structures
Gradual response to change in product.
Gradual elevation of product temperature
Requires significant exhaust rates
Potential for color cross contamination
 Convection Ovens
19

Transfers heat to the powder coated part by circulating heated air

around the part.
Burner Box
Exhaust
Gas Burner Stack

Fan
Return Air Opening

Discharge Duct

Insulated Oven Shell

 General Exhaust Rates
20

Based on powder volume & gas volume

Powder pounds/hour x 9% x 360 ft3 x 4 60 minutes = SCFM

Add for byproducts of combustion: Btu/h 5700 = SCFM
Correct for temperature: SCFM x 1.62 = CFM (@400 F)

Works well for most non-appearance parts and dark colors require
Some ovens may require higher exhaust
Clear powder coatings
Polyester urethane
High quality appearance parts
Light colors
 Powder Discoloration Problems
21

Insufficient exhaust volume

Powder over-bake
 Building Heat Gain
22

Building conditions
Air supply & ventilation

Heat containment & oven design

Insulation on oven & washer
 Air Pressure in Building
23

Exhaust takes air Exhaust takes air

out of the building out of the building

Make-up air infiltrates Supply air is introduced through AMU

 Heat Containment
24

Bottom entry/exit to elevated oven

Powered air curtain at openings
Heat relief hood at openings
Extended vestibule
 Bottom Entry/Exit Air Seal
25

Energy efficient
Does not disturb uncured powder at entrance
Requires elevated ovens
Increased capital cost
 Powered Air Curtain
26

Provides some control of heat loss

Higher capital cost for oven Fan

Requires high velocity for effective

heat containment
Cure oven entrance should not
have an air curtain
Not effective on very large
openings
 Heat Relief Hood
27

Does not prevent heat loss

Low capital cost
Does not disturb coated parts
Relieves building heat gain
 Extended Vestibule
28

Creates a good barrier to rapid heat loss

Low capital cost
Requires more floor space
Reduces energy use
Vestibule

Vestibule
Entrance

Exit
Heated Zone
 Batch & Conveyorized Ovens
29

Batch ovens
Flexible for size & cycle

Good heat containment when doors are closed

Uniform heating

Significant heat loss when doors are opened

Conveyorized ovens
Larger volume from continuous movement

Continuous heat loss

Usually larger burners

 Batch Cure Ovens
30

Size to hold enough loads to avoid bottlenecks

Separate drying oven if possible
Doors on one end or both?
 Batch Oven Features
31

Use guide rails on oven floor

Allow space to move carts freely
Insulate the floor
 Conveyorized Oven
32

Allow for heat loss & containment

Straight pass oven will lose more heat at the ends
 Infrared Ovens
33

Infrared heating is the transfer of thermal energy

in electromagnetic waves
Thermal energy is directly transferred from the
infrared heat source to the part substrate
Energy can be absorbed by coating, transmitted to
substrate surface or reflected from surface
Electromagnetic Wavelength Spectrum
34
.76 um 2 um 4 um 103 um
Short Medium Long
wave wave wave

Gamma X-rays Ultraviolet Infrared Microwave Radio

Rays Rays Waves

1 pm 1 nm 1 um 1 mm 1m 1 km
10-6 um 10-3 um 103 um 106 um 109 um
Visible
Light
 Wavelengths of IR
35

Short Wavelength
2150 - 4000F Heat Source (0.8 - 2 micron wavelength)
Response time Instantaneous
Source - Electric
Color - Bright White
Medium Wavelength
845-2150F Heat Source (2-4 micron wavelength)
Response time 60 seconds
Source Gas or Electric
Color - Orange
Long Wavelength
0-845F Heat Source (4-11 micron wavelength)
Response time 5 minutes
Source Gas or Electric
Color - Dark
 Zoning of Infrared Ovens
36

Z1

Z2

Z3
Product Flow
VERTICAL ZONING

Z1 Z2 Z3 Z4
Product Flow
HORIZONTAL ZONING
Zoning of IR

37
 Using IR & Convection Effectively
38

Convection can be used alone or with IR

IR can be used alone or in combination with other cure technologies
Correct application of more precise technology requires testing &
precise application for success
Attention should be given to selection of the appropriate emitter for
response time (line interruption & breaks)
 Oven Troubleshooting
39

Dirt & contamination problems

Under-cure
Over-cure
Recoat failure
Oven temperature balance
Oven turbulence
Oven fouling
Cleanable Interior
40
Return Air Filtration
41
Filtered Burner Inlets
42
 Under-cure
43

Insufficient time and/or temperature

Soft film
Poor adhesion
Higher gloss
Lack of film performance
 Over-cure

Excess time and/or temperature

Discoloration
Brittle film
Color shift
Low gloss
Inter-coat adhesion failure

44
 Temperature Balance

Plant air negative air, cross drafts, tunneling effect

Adequate re-circulation fan volume
Duct design
Duct adjustment

45
Temperature Recorder

46
Measurement of Temperature in Oven
47
Use Recorded Data for Adjustment
48

Wireless or Wired Systems

Typical 3 Pass Oven
49
Chart Before Balance
50
 Chart After Balance
51

c111000a
550.0 550.0
Zone 1 Zone 2 Zone 3 Zone 4 Zone 5 Zone 6
500.0 500.0

450.0 450.0

400.0 U
M 400.0
L
350.0 350.0

300.0 300.0

250.0 250.0

200.0 200.0

150.0 150.0

100.0 100.0

50.0 50.0
50 100 150
0.00 160.00
(Dis tanc e Graph) Units in f eet. Ov en s peed: 8 f t/min

00:05:00 00:10:00 00:15:00

00:00:00 00:20:00
(Elaps ed time f rom Zone 1) Minor interv al = 00:01:00
A ir High A ir Low Part
F F F
 Oven Air Turbulence
52

Plant airflow negative air, cross drafts, tunneling

effect
Air curtain turbulence air velocity blows off uncured
powder
Air balance problems incorrect adjustment of
discharge air
Supply duct placement poor discharge duct design
 Proper Exhaust Volume

Pounds of powder per hour + By-products of

combustion
Low exhaust volume can cause smoke in the plant,
fouling & discoloration
Excess exhaust volume is a waste of $$$$

53
 Oven Maintenance
54

Have burners, fans & controls inspected & serviced

annually
Regularly clean the oven interior
Regularly measure temperature & balance air as needed.
Follow maintenance manual for lubrication & routine
maintenance
 Oven Maintenance
55

Lubrication
Fan bearings
Filtration
Fresh air filter
Combustion blower
Recirculation filters
Safety checks
Gas train components
Air flow switches
 Forrest Paint
Powder Coating Program
1

RACKING & FIXTURES

RODGER TALBERT
TALBERT CONSULTING
 Hanger Goals
2

Presentation easy access to all surfaces

Grounding earth grounding is essential to control
of the process
Hanger length avoid getting powder on the
overhead hanger (ground sources)
Drainage angle part to remover water if it was
prepared chemically
Presentation
3
 Grounding
4

Path from part to earth ground

Clean contact

Clean contact from hanger to rail

Clean rail system or hanger bar

 Hanger Length & Clearance
5

Hanger Attachment
Point

27 Minimum

Part
6 Part Clearance

6 Part Clearance
Hanger Considerations
6

No angle traps water!

WATER

Angle allows water to drain.

 Racking Design Issues
7

Stable racks steady position, good access for

spray guns
Dense racking spray more part than air
Dedicated tooling special tooling can save money
& improve productivity
Pre-rack stations better use of space
Rack inventory & maintenance ground
Proper Racking
8
 Hanging Methods
9

Wires
Rods
Fixtures
Chains
Improper Racking
10
 Hooks
11

Inexpensive
Flexible
Easy to maintain
 Custom Made Racks
12

Accuracy
Consistency
Density
Stability
High yields
Output
 Racking Cost
13

House Racks
2 pieces/rack

Special Tool
4 pieces/rack
 Racking Cost
14

Line Speed 8 FPM

Rack Spacing 2 centers
Throughput 8 FPM x 60 M = 480 FPH
480 FPM 2 centers = 240 racks/hour

House Racks: 240 x 2 pieces/rack = 480 pieces/hour

Special Tools: 240 x 4 pieces/rack = 960 pieces/hour

 Fixed Cost per Piece
15

$400.00 480 pcs = $0.83/piece

$400.00 960 = $0.42/piece

Savings is $0.41/piece with special tooling

 ROI
16

Pieces per Month ROI in Months

1,000 9.75

2,000 4.9

3,000 3.25
Custom Tooling
17
Pre-racked Parts
18
 Parts Masking
19

Effective masking easy to apply, easy to remove,

no residual problems
Cost per mask
Removal before or after cure
How many uses?
Can it be cleaned & reused?
 Soft Masking Options
Tape
Caps
Plugs
Tubing
Die-Cuts

20
 Tape
21

Most Common Materials

Crepe 300F
Green Poly 400F
Blue Poly 400F
Red Poly 400F
Polyimide 500F
Glass Cloth 500F
 Plugs
22
Plugs are available for all finishing operations and are used to mask both
through holes and blind holes.

Standard Material
Silicone Rubber
Temperature Range up to 500F
Multiple Uses
Variety of Colors
EPDM Rubber
Temperature Range up to 375F
Limited Reusability
Less Expensive Option
Limited Colors
 Custom Soft Masking

Rubber Molded
Die-Cut Materials

23
 Eco-Friendly Masking
24

Silicone multiple use

Disposable recycled rubber
Cork renewable, no trees needed, remove before
cure
Vacuum & air masks
Vacuum & Air Masking
25
 Hard Mask Options
26

Tubing on the rack holds the part and masks the stud.
 Hanger Maintenance
27

Durable construction
Keep them in good repair
Try to run full racks
Keep the contact points clean
 Benefits of Hanger Cleaning
28

Ensures good earth ground for electrostatic

application
Improves application performance & uniformity
Provides safe application (Less than 1 Megohm
resistance to ground)
Chemical Strip Tank
29
Fluid Bed Stripping
30
Burn-off Oven
31
Molten Salt
32
 Forrest Paint
Powder Coating Program
1

POWDER COATING MATERIALS

Resins plus Pigment/Additives
2
 Powder Manufacture
3

7.Package 1.Formulation

6.Sieve
2.Pre-mix

5.Grind 3.Extrusion

4. Chip
 Production of Powder Coatings
4

Blending Weighing

Grinding/Classifying Chipping Cooling Extrusion Controls

Mixing
5
Pre-Mix Operation
6

Motor
Pre-Mix Operation
7
 Extrusion
8

Pre-mixed raw materials

Extruder

Chipper

Chilled rollers

Cooling belt
Powder on the Cooling Belt
9
Powder Mill
10
Powder Manufacture Grinding
11

cyclone

Chip hopper

Sieve
Sieve

Grinder
 Thermoset Powder Coating Systems
12

Epoxy
Urethane Polyester
TGIC Polyester
HAA (TGIC Free)
Acrylics
Hybrids
 Powder Chemistry Selection
13

Indoor or outdoor use

Mechanical properties needed
Smoothness
Scratch resistance
Mar resistance
Impact resistance
Hardness

Chemical properties needed

Corrosion resistance
Moisture resistance
Other
 Natural Weathering Gloss Retention
14
Gloss Loss (%)

Months of South Florida Exposure

 Urethane & TGIC Polyester
15

Urethane TGIC

Film Thickness Generally thinner Thin to thick

Chemical Resistance Very good Very good

Edge coverage Fair Good

Smoothness Excellent Good

 HAA Based Polyester
16

Exterior durable powder coating that does

not contain TGIC.
Non-Emissive
European Compliant
Excellent transfer efficiency
Can outgas at thick films
Very good corrosion resistance
 Super Durable Polyester
17

Super Durable TGIC & TGIC-Free Polyester

Superior corrosion resistance
Can be formulated with Infrared Reflective
pigments for superior color retention & meet
AAMA 2604
 Acrylics Powder Coatings
18

Aluminum Automotive
Wheels
Brass Hardware
Aluminum Boats
Automotive Accessories
 Fluoropolymer
19

FEVE and PVDF resins

Contains Infrared Reflective
pigments for superior color
retention
One coat system
Excellent durability on exterior
architectural building components
Good hardness and flexibility
Designed to Meet AAMA 2605
specifications
 Interior Products
20

Epoxy; Film-forming binder, First Hybrid; an epoxy-modified polyester

Powder Coating Developed or an epoxy-modified acrylic

Thin or Heavy Film Builds Typically Epoxy-Polyester

Excellent Chemical Resistance Good Resistance Properties
Excellent Corrosion Resistance Good Flexibility
Mechanical Properties Thin Film
Flexibility Enhanced Over-bake
Improved Electrostatic Edge
 Fusion Bond Epoxy (FBE)
21

Epoxy Resin System

Can be cured with Residual Heat of Substrate
Very Fast Gel time (Seconds)
Extremely good corrosion resistance
properties (Cathodic Disbondment)
 Higher Temperature Resistant Powder
22

Heat Resistant Powder 350F to 400F

Medium Heat Powder 400F to 550F
High Heat Powder 800F to 1,000F
Silicones

Limited to blacks & textures on extremely high temperatures

Outstanding Color/Gloss Retention

Pretreatment Sensitive blasting recommended

 Metallic Powder
23

Multiple ways to create a metallic appearance

Bonded; adhesion or secured joint of coating to
metal flake
Dry Blend; a process where material is blended
without melting
Extruded; a process utilizing heat and mechanical
kneading to achieve a homogenous mixture.
 Textures
24

There are multiple textured looks and various ways to

achieve a textured look in powder coatings.
Wrinkle

Mini-Texture

Rolling Texture

Tight Ridge Texture

 Antimicrobial Coatings
25

Developed to prevent the growth, spread and

migration of bacteria, yeast, and mold
Either drug based organics or precious metal
inorganic such as silver
Can be applied by same methods as other
powder coatings
Uses to include medical equipment, school
lockers, counter surfaces, door hardware etc
 HOW DOES IT WORK?
100% inorganic aluminosilicate carrier
Stable to 800 C and through a pH range of 3 - 10

26

Moisture in the air causes

a controlled release at a
slow and steady rate to
provide efficacy.

Ag+ is released through a proprietary

ion exchange process
 Low Temperature Cure
27

Ultra-low bake somewhat less stable than standard

cure; may not be as durable
250F for epoxy
325F for polyester
Ultra-violet cure more costly; line of sight; costly
cure lamps
 Comparison of ULB and UV
28

ULB

Powder application Melting and cross-linking Cured coating

UV

Powder application Melting/flowing UV cross-linking Cured coating

 Specialty Products
29

Multi-Color
Pearlescent
Fluorescent
Anti-Corrosion Primers
Sublimation
Properties & Performance of Thermoset Powder
30

Broad Color Range

Matte to high Gloss
Smooth, Texture,
Wrinkle, Special Effect
Metallic, Clear,
Translucent
Layering options for
performance
 Six Causes for Powder Failure
31

1. Substrate
2. Product design
3. Pretreatment
4. Application
5. Coating selection
6. Cure
 1.Variables in Substrate
32

Substrates can change when vendors,

batches or processes change
 Substrate Variables
Substrate Variables

Composition of Alloy
Soils on Surface Surface Films

Oxidation
 Substrate Variables

Impregnation Inks & Markers

Residuals After Cleaning
Marker on Substrate
Bubble Wrap Transferred to Surface
Oil Contamination
 Substrate Conditions

Telegraphing
 2. Product Design
39

How can product design cause a failure?

Difficult to clean areas
Multi-metal parts
Impossible to coat areas
Sub-standard design for end use environment
Areas that trap moisture or water
Excessively sharp edges
Overlapping seams
 Poor Construction
40

Blisters in Coating;
No Drainage from Rail
Trapped Salt Water
Rust Bleeding From 0-T Bend Area

41
 Variables in Product Design
42

Water traps
Sharp edges
Substrate condition
Castings (outgassing)
Post handling
Sharp Edges, Poor Coverage
43
 3. Poor Preparation
44

Preparation is critical to successful

performance
 Importance of Proper Pretreatment
45

Powder coatings need a clean, well prepared

substrate
Surface preparation can lead to high performance or
failure
Cleanliness & proper preparation of the substrate is
critical to the performance of the powder coating
Evaluate Part Condition
46

Rust will lead to corrosion

Failure Due to Poor Pretreatment
47

Premature Corrosion Adhesion Failure

 Pretreatment is Substrate Dependent
48

Substrate Methods Available

HRS Blast; pickle

CRS Chemical clean, conversion coating

Galvanized Brush blast; wash & rinse

Aluminum Blast; clean, conversion coating

Other Clean; abrade; dry

 4. Application
49

Application plays a huge roll in the

over all performance & potential
failure of a powder coating
 Must Have Good Earth Ground
50

Check ground resistance value

NFPA 33
Use MW-meter (500 V)
Resistance < 1 MW
Review hook/rack design
Self-masking
Contact point
Sharp edges
Cleaning schedule
Burn-off
Blasting
Stripping
Impact of Thicker Film Orange Peel
51

Insufficient
Q Attraction

Strong Mirror
Q Image Attraction
Impact of Heavy Film
52
 Impact of Particle Size
53
% of Total

TE = 70%

TE = 30% TE = 50%

Particle Size in Micron

 Halo (poor grounding)

Light Coverage, Unwanted texture

Poor Coverage in Corners (Faraday Cage)

54
 Starring Back-Ionization

55
 5. Selection of Powder
56

Choosing the right powder for the

application is of the utmost
importance
All Powders are not Created Equal !!!!
57
 Selecting the Right Powder
58

Match product performance to end use

Systematically evaluate tradeoffs
Confirm application properties
Measure results
 Powder Properties
59

Attribute Options

Smoothness PCI 1-10

Impact Flexibility vs. hardness

Gloss Low to High

Color Appearance & match

Cure Fast/low temperature or standard

Mar resistance Soft to hard

Other Chemical & mechanical

 Optimized Formulations
60

Application characteristics impacted by

formulations are:
First pass transfer efficiency
Faraday penetration
Reclaim /re-use
Edge coverage
Film uniformity
Layers
61
 Powder in Layers

Clear-coat
Powder Top Coat Powder Top Coat Powder Top Coat Powder Top Coat
Zinc Containing Primer Powder Primer Powder Primer
Substrate
Substrate Substrate Substrate

1-layer
2- layer 2-layer 3-layer

Pick the right layering system for the application

62
 Specific Gravity
63

Key factor in coverage

equation
Influenced by raw
materials
Fillers/extenders
Pigments
May decrease weather-
ability
1.7 SG 1.5 SG 1.3 SG May increase wear on
application equipment
Same Weight
 Powder Coatings as Engineered Products
64

Suitable for the end-use environment

Sunlight
Moisture
Abrasion
Corrosives
From low standards to extreme standards
Indoor furniture
Dockside railing
Applied cost
Coverage as needed
Efficient material use
Performance as needed
 Chemical & Mechanical Properties
65

Film Build
High Build
Thin Film

Edge coverage
Faraday penetration
Out-gassing resistance
Hardness/softness
Chemical resistance (oil, detergent, other fluids)
 6. Cure
66

Powder coatings must be 100% cured to

get optimum performance and
appearance characteristics
 Curing Thermoset Powder
67

Powder Melting/flowing Cross-linking Cured coating

Application
Proper Cure
68
 Total Cycle Time for Cure
69

Bring-up time the time required to elevate metal

temperature to desired level
Dwell time the time that the metal must remain at
the threshold temperature in order to reach full cure
Total cycle time bring-up + dwell
Total cycle time increases with increase in metal
mass
Convection Oven Graph
70
 Testing for Cure
71

Observations color, gloss, hardness

Chemical resistance test
MEK or Acetone solvent rub test
Must be done with a known cured sample for
comparison
Lab test Differential Colorimetry Scan (DSC)
72
 Powder Color
73

Standard colors (RAL, Pantone, ICC, etc.)

Custom colors made to customer specification
Color matching matched to a sample
Metamerism lighting & angle affect the color seen;
light input behaves differently on different colored
pigments
 Three Dimensions of Color
74

Lightness neutral gray scale from white to black;

vertical axis
Saturation more or less saturation; radial distance
away from vertical axis
Hue bluer, yellower, redder; angular distance
around the vertical axis
Requires a minimum of four colorants to make
adjustment easier
 Color Sphere
75

Yellowness

Greenness

Redness

Blueness
 Color Measurement
76

Visual match
Colorimeter
Just Noticeable Difference (JND)
Units of Delta E
Color master standard
Metamerism
77
Light Source Metamerism
78
Pigment Combinations Affect Metamerism
79
 Powder Storage & Handling
80

Products should be stored below 80F

Some low cure powders require 65F
Humidity should be 50-60%
Shelf life typically 12 months
Shipping concerns in warm climates
Conditioning
 In Process Storage
81

Issues affecting powder stability

Moisture-in-air absorption

Cross-contamination of partially used

materials
Over-exposure to heat

Inactivity or exceeding shelf life

 Forrest Paint
Powder Coating Program
1

QUALITY ASSURANCE
FOR POWDER COATING
 Goals
2

Improve consistency
Reduce cost
Maximize throughput
Deliver maximum volume of acceptable parts per
hour
 Critical Factors
3

Objective (not subjective) methods

Based on what the customer expects & is willing to
pay for
Evaluation should not automatically be changed
when a quality problem arises
Should avoid over-engineering
Should be clear to all employees
Is consistent from one employee to another
Should be clearly documented
 Quality Assurance Should Include
4

1) An understanding Market Requirements

2) Requirements for specification
3) Procedures for tests & evaluation methods
4) Written Specification
5) Process Control
6) Training and Leadership
 1) Understanding Market Requirements
5

Interview & evaluate

Your sales & marketing team

Your competition/leaders & followers

Alternative technologies

Leadership within your organization

Your Customers
Sales & marketing; NOT purchasing agents
Determine Appearance & Performance Criteria
6

Criteria Importance

Color & Gloss Very Important

UV Resistance Critical

Mar Resistance Important

Corrosion Resistance Critical

Hardness Low Importance

Film Thickness Important

Film Appearance (particulate) Low Importance

 Atmospheric Conditions
7

Category/ Performance Expectations Example

1. Low Performance Very Low Performance Brake Pad
2. Mild Interior Low Performance Low-cost
Furniture
3. Moderate Interior Good Performance Better Furniture
4. Quality Interior Good Performance Exercise
Equipment
5. Mild Exterior Good Performance Decorative Fence
6. Moderate Exterior Very Good Performance Lawn Furniture
7.Architectural/Marine/Industrial Superior Performance High-end Railing
/Tropical Exterior
Example Category 5, Mild Exterior
Aluminum Ornamental Fencing
8
 Category 5 Difinition
9

Category 5: Moderate Exterior Moderate

Performance

This category includes products that are used

outdoors but do not require significant resistance to
corrosive materials or exceptional resistance to
ultra-violet (UV) light. Products that are used in
exterior environments require a better pretreatment
and a suitable UV resistant powder such as
polyester.
Example Category 6, Moderate Exterior
Lawn Furniture
10
 Category 6 Definition
11

Category 6: Moderate Exterior

Very Good Performance
This category includes products that are expected to
provide substantial resistance to sunlight and
corrosive materials and provide good performance
and longevity. These products may be used in a
variety of environments that could include extreme
temperatures or humidity conditions. This category of
products will typically not provide exceptional long-
term performance when used in seacoast or similar
harsh environment.
 2) Determine Requirements of Specifications
12

How does the product need to perform?

Appearance after a few years in service
Corrosion control after a few years
Gloss retention after a few years
Film thickness requirements
Define adhesion and hardness
Identify special or down stream processes to consider
Identify special packaging needs to consider
Define color(s) and color specification
 3) Tests and Evaluations Methods
13

What test will be used and how often?

Appearance after a few years in service AAMA 2604
Corrosion control after a few years 1500 ASTM B117 Salt Fog
Gloss retention after a few years 30% of greater after 5 Years
Film thickness requirements 2.5 - 4.0 (A Surfaces)
Define adhesion & hardness 5B & 2H
Identify special or down stream processes to consider Labels
Identify special packaging needs to consider Corrugated Fiber
Define color(s) & color specification Max 1.0 DE from Master
Tools of the Trade
14
Film Thickness

Conical Mandrel Bend Test

15
 Adhesion Testing

Pencil Hardness
Salt Spray Cabinet

16
 Weathering
17

EMMAQUA

Panel Farm
UV Test Cabinets
18
Light Cabinet
19
 4) Written Specification
20

Definition of expectations for appearance &

performance
Includes all facets of the performance, application
and evaluation process
Outlines the standards that must be met & the
measurements that will be used
 Written Specification
21

Scope
Surface preparation
Coating material(s)
Application
Testing & sampling
Film properties
Appearance
Gloss
Color
Film thickness
 Test AAMA 2603-13 AAMA 2604-13 AAMA 2605-13
(polyester) (Superdurable (Fluoropolymer)
American Architectural Manufacturing Association polyester)

Dry film hardness Yes 22 Yes Yes

Dry film adhesion Yes Yes Yes
Wet film adhesion Yes Yes Yes
Boiling water resistance n/a Yes Yes
Impact resistance Yes Yes Yes
Abrasion resistance n/a Yes Yes
Muriatic acid resistance Yes Yes Yes
Mortar resistance Yes Yes Yes
Nitric acid resistance n/a Yes Yes
Detergent resistance Yes Yes Yes
Window cleaner resistance n/a Yes Yes
Humidity resistance 1500 hours 3000 hours 4000 hours
Salt spray resistance 1500 hours 3000 hours 4000 hours
South Florida weathering 1 year 5 years 10 years
Color retention Slight fade < 5 Delta E (Hunter) < 5 Delta E (hunter)

Chalk resistance Slight chalk < No. 8 < No. 8

Gloss retention n/a (slight > 30% > 50%
chalk/fade)
Coating erosion n/a (no crazing) < 10% < 10%
 Must Have List
23

Film Thickness
Appearance Visual Comparisons
Color, Gloss, Smoothness, Texture and/or Metallic

Reject Evaluation Method

Consistent Light source for Evaluation
Method to Evaluate Cure
 Work With the Experts
24

Cooperative effort between end user and

suppliers
Wide variety of process combinations
Prioritize process evaluation requirements
Simple considerations:
Cure time and temperature
Substrate type, soils and pretreatment
Application method
Part configuration
 6) Training and Leadership
25

Quality Assurance Starts at the Top

Must have top level management commitment

Establish a quality team

Include management and appropriate

representatives
Require periodic reviews with quality team

Include quality as part of daily/monthly meetings

Include quality as part of performance reviews

Management Commitment to Training

Include quality team and line personnel
 6) Training and Leadership
26

Develop Key Internal Trend Analysis

Customer rejects and/or returns

On-time shipping performance

Get Customer Satisfaction Feedback

Create an online survey (SurveyMonkey.com)

Conduct face-to-face interviews with key accounts

Review/Upgrade Quality Manuals Quarterly

Improved Quality will Add to the Bottom Line
 Defect Analysis
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Recording of defects
Identification of cause
Corrective adjustment
 Defects
28

Adhesion Failure
Poor pretreatment
Inadequate film
Wrong coating

Back-ionization
Excess ions
Thick film
Gun too close
 Defects
29

Blistering
Moisture under film
Moisture in compressed air

Chalking
Wrong powder
Incorrect cure
 Defects
30

Corrosion
Poor surface preparation
Inadequate film thickness
Wrong coating
Under-cure

Craters
Silicone contamination
Oil or other liquid on surface
 Defects
31

Outgassing
Casting porosity
Micro-fissure in steel
Galvanized surface
Contamination
Overbake
Excess time in oven
Excess temperature