BASF Handbook: Basics of Coating Technology

Artur Goldschmidt, Hans-J. Streitberger

1 Introduction
1.1 Definition, Tasks and Economic Importance
1.2 Retrospective
1.3 Bibliography

2 Coating Material
2.1 Raw Materials
2.1.1 Film Forming Agents
2.1.1.1 Natural Materials
2.1.1.2 Synthetic Resins
2.1.2 Solvents
2.1.2.1 Theory of Solubility
2.1.2.2 Physical Properties
2.1.2.3 Chemical and Physiological Properties
2.1.2.4 Important Solvents for Coatings
2.1.3 Pigments and Extenders
2.1.3.1 Physical Principles for Chroma and Hiding Power
2.1.3.2 The Most Important Pigments for Coating Materials
2.1.3.3 Extenders
2.1.4 Plasticizers and Additives
2.1.4.1 Plasticizers
2.1.4.2 Additives
2.1.5 Summary
2.2 From Raw Material to Coating Material
2.2.1 General Rules on Drawing up Formulations
2.2.1.1 Purpose and Quality
2.2.1.2 Production Resources, Application Systems and Object to be Painted
2.2.1.3 Function in Paint System
2.2.1.4 Cost Effectiveness and Availability
2.2.1.5 Occupational Health, Safety and Environmental Protection Regulations
2.2.2 Material Flow in a Paint Factory
2.2.3 Theory of Dispersion
2.2.3.1 Pigment Specific Properties for Dispersion Processes
2.2.3.2 Wetting and Decomposition of Agglomerates
2.2.3.3 Stabilization of Pigment Dispersions
2.2.3.4 Optimum Mill Base Formulation
2.2.4 Production of Coating Materials
2.2.4.1 Processing Sequences in a Paint Plant
2.2.4.2 Agitation and Agitators
2.2.4.3 Dispersersing and Dispersers
2.2.4.4 Separation Processes in the Manufacture of Paint
2.2.5 Summary
2.3 Characterization of Coating Materials
2.3.1 Measurement Accuracy
2.3.2 Testing Raw Materials and Coating Materials
2.3.2.1 Safety and Environment Related Performance Indicators
2.3.2.2 Chemical Characterization
2.3.2.3 Physical Data
2.3.3 Pigment Specific Tests

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2.3.3.1 Indicators of the Pigment as a Raw Material
2.3.3.2 Tests with the Pigmented Coating Material
2.3.4 Processibility of Coating Materials
2.3.5 Summary
2.4 Literature

3 Coatings
3.1 From Coating Material to Coating: The Film Formation
3.1.1 Wetting and Flow
3.1.2 Solidification of the Film
3.1.2.1 Physical Drying
3.1.2.2 Chemical Curing
3.1.2.3 Flows in the Solidifying Film
3.1.3 Film Shrinkage
3.1.4 Special Features of High Solid Paints and Waterborne Paints
3.1.5 Monitoring the Film Forming Process with Measuring Instruments
3.1.5.1 Flow and Sag
3.1.5.2 Film Formation of Air Drying Paints
3.1.5.3 Indirect Methods
3.1.6 Summary
3.2 Properties and Testing the Coatings
3.2.1 Film Thicknesses
3.2.1.1 Wet Films
3.2.1.2 Dry Films
3.2.2 Dry Film Density
3.2.3 Measurement of Voids in Coating Films
3.2.4 Visual Properties
3.2.4.1 Gloss
3.2.4.2 Color and Coloristic
3.2.5 Mechanical Properties
3.2.5.1 Adhesion
3.2.5.2 Elasticity
3.2.5.3 Hardness
3.2.5.4 Abrasive Resistance and Mar Resistance
3.2.5.5 Other Tests
3.2.6 Summary
3.3 Durability of Coatings
3.3.1 Fundamental Features of Ageing
3.3.2 Ageing Tests
3.3.2.1 Test Methods for Surface Durability
3.3.2.2 Corrosion Protection Tests
3.3.2.3 Chemical Resistance
3.3.3 Summary
3.4 Literature

4 Coating Technology
4.1 Substrate Impact
4.1.1 Wood and Wood Materials
4.1.1.1 Wood as a Material
4.1.1.2 Wood as a Workpiece
4.1.1.3 Pretreatment of Wood
4.1.1.4 Surface Refinement of Wood Panels
4.1.2 Metallic Materials
4.1.2.1 Properties of Metals

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4.1.2.2 From the Material to the Workpiece
4.1.2.3 Pretreatments
4.1.3 Plastics
4.1.3.1 Plastic Types and Properties
4.1.3.2 Pretreatment
4.1.4 Mineral Substrates
4.1.4.1 Concrete, Mortar, Plaster
4.1.4.2 Glass
4.1.5 Other Substrates
4.1.5.1 Rubber
4.1.5.2 Leather
4.1.6 Work Piece Design and Coatability
4.1.7 Summary
4.2 Paint Processing
4.2.1 Processing of Wet Paints
4.2.1.1 Dip Coating (Object Taken to Paint)
4.2.1.2 Brushing, Manual and Mechanical Roller, Flood and Curtain-Coating Methods
(Paint Applied Directly to the Object)
4.2.1.3 Spray Processes (Paint Applied Indirectly to the Object)
4.2.1.4 Paint Supply Systems
4.2.1.5 Booth Conditioning and Overspray Elimination
4.2.1.6 Automated Systems and Robots for Paint Processing
4.2.1.7 Conveyors
4.2.1.8 Paint Removal
4.2.2 Processing Powder Coatings
4.2.2.1 Retrospective
4.2.2.2 Plant and Equipment Details
4.2.2.3 Powder Coating Materials
4.2.2.4 Powder-Specific Test Methods
4.2.3 Summary
4.3 Drying and Curing
4.3.1 Film Formation by Heat Transfer
4.3.1.1 Theory
4.3.1.2 Oven Design
4.3.2 Curing by UV and Electron-Beam Radiation
4.3.3 Summary
4.4 Literature

5 Safety, Environmental Protection and Health

5.1 Legislative Framework
5.2 Safety
5.2.1 Manufacturing
5.2.2 Storage
5.2.3 Transportation
5.2.4 Application
5.3 Environmental Protection
5.3.1 Exhaust Air
5.3.2 Wastewater
5.3.3 Recycling and Disposal
5.4 Health
5.5 Ecobalances
5.6 Environment Compatible Paints and Coatings
5.6.1 High Solids
5.6.2 Waterborne Paints
5.6.3 Slurry

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5.6.4 Powder Coatings
5.6.5 Radiation Curable Paints and Coatings
5.6.6 Other Coating Systems
5.7 Economy of Coating Processes
5.8 Literature

6 Principles of Quality Management

6.1 Evolution of Quality Concepts over Time
6.2 Defects in Coating Processes and Applied Coatings
6.2.1 Identifying Defects and their Causes
6.2.2 The Most Frequent Causes of Surface Defects
6.2.3 Summary
6.3 Material Control
6.4 Defect Prevention by Process Control and Control Loops
6.5 Quality Management
6.6 Literature

7 Coating Industries
7.1 Automotive OEM Coating
7.1.1 Pretreatment
7.1.2 Electrocoating
7.1.3 Seam Sealant and Underbody Protection
7.1.4 Primer Surfacer
7.1.5 Topcoat Application
7.1.6 Repair in Automotive OEM Lines
7.1.7 Outlook
7.2 Automotive Refinishing
7.3 Automotive Supply Industry
7.4 Coil Coating
7.5 Commercial Vehicles
7.6 Mechanical Engineering
7.7 White Goods
7.8 Building Supplies
7.9 Rail Vehicles
7.10 Wood Coating
7.11 Other Fields of Application
7.11.1 Protection of Structures
7.11.2 Steel Furniture
7.11.3 Aviation Industry
7.11.4 Electrically Insulating Coatings
7.11.5 Communication Equipment
7.11.6 Road Marking Paints
7.11.7 Shipbuilding
7.11.8 Miscellaneous Coating Applications
7.12 Literature

8 Industrial Standards
8.1 General Information on Standardization Work
8.2 Actual Industrial Standards and Specifications for Coatings
8.3 Literature

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9 Appendix
9.1 List of Physical Constants
9.1.1 Latin Symbols
9.1.2 Greek Symbols
9.2 Web-Addresses of Interest for the World of Coatings
9.2.1 Organizations
9.2.2 Publishing/General Informations
9.2.3 Research Institutes/Universities/Colleges
9.2.4 Miscellaneous
9.3 Acronyms/Abbreviations
9.4 Picture Sources

10 Index

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