Outlined above are the basics of the powder cutting process and equipment, and some of the considerations that may be taken into account by manufacturers when deciding whether powder coating is the most optimal solution for their particular coating application. Was the oven's atmospheric temperature too low? The increase in coating Tg build up is much more detailed compared to the reverse impact results depicted in Figure 2.
Reverse impact is used as a measure for sufficient network formation. But how do you know what to do to correct the problem? For this reason it is recommended that bulk containers of powder coating be allowed to equilibrate to application room temperature for at least several hours prior to opening of the container. Let's candidly discuss each of these profiling issues in more detail. Typical Cure Development.
Less Orange Peel, cures fully every time etc. If you are trying to shoot chrome powders sometimes the IR gun will bounce off the reflective surface and not read accurately. Many PPG powder customers deliberately set oven conditions so that there is a comfortable safety margin between the minimum conditions specified in the cure curve and actual. An electrostatic paint sprayer is used for the application process. For manufacturers who cannot perform in-house powder coating operations, their prototype, short, and long production run jobs can be handled by a job shop or finishing service provider who offers powder coating services. Although the bake/cure process generally follows after the coating is applied, there are instances when it's preferable to heat the substrate first. PPG has all-color approval for: Underwriters Laboratories' website displays basic information about recognitions, by company to whom the recognition was granted. Increased Durability. You may have to register. There is also an alternative option called electrostatic fluidized bed powder coating, which generates a cloud of electrically charged powder particles above the fluidized bed through which a part is passed to be coated. They demonstrate higher resistance to impact, moisture, chemicals, and wear, and offer greater protection from scratches, abrasion, corrosion, fading, and general wear. 3 to 1, 000 microns with a source temperature of 100° to 860° F. The Frequency Spectrum. It is not uncommon to have one side of a part 50 degrees off from the other side of the part.
The final finish achieved ranges from matte to glossy, and clear to metallic. 375°F for 15 minutes (PMT). At this distance you will notice the temperature will level out. More room for error (safety feature). For example, with a box oven, temperature drops during loading. That's the best we could do I guess? The requirements and specifications demanded by a particular powder coat—e. Acedemic Press 1981, London, page 489-498. Generally, direct profiling is performed in applications where it would be too expensive to use a test piece, and where thermocouples can be applied to the product without causing damage to the surface coating. I think I have read this and read that but can't remember every thing for sure my self. While there is no powder coating product that can eliminate all occurrences of outgassing in severe cases, there are ways to reduce outgassing occurrences during the application process, and there are products PPG makes that are designed to reduce the chances outgassing occurs. If the temperature in the oven is not within the necessary range, or it is significantly inconsistent inside the cabin, you'll end up dealing with curing problems even if they are not immediately detectable.
More flexible in thick coatings. Therefore, when curing a paint or powder coating on products with complex geometries, it is essential that temperature measurements are made at carefully selected locations to discount differential heating of surfaces exposed to or shielded from the infrared radiation. And coat them first. During the curing cycle, volatile ingredients may be emitted from the surface which can cause surface contaminants and imperfections in the finish coat. I tell you the truth, not one question asked is a Dumb question! In deciding between completing powder coating operations in-house or outsourcing operations to a job shop or contractor, it is important for a manufacturer to understand the costs and benefits of both options in order to choose the one best suited for their powder coating application. Powder Coating Troubleshooting Guide. This helps if you like to cure your substrate just a little longer to insure a good cure or even if you forget about the substrate. For example, the cure schedule for a typical polyester powder coating is 10 min at 390°F (200°C). Table 1 – Comparisons between Types of Powder Coating Material. This process allows for a wider range of coating thicknesses. The electrically-charged particles can then adhere to the part's electrically grounded surface and will remain adhered as long as they maintain some of their charge. Understanding An Oven Data Recorder Report.
The arrow shows the cure time needed for the cure temperature specified. PPG powder coating product lines with exceptional chemical resistance are the best candidates for anti-graffiti applications: PPG has the ability to make anti-graffiti powder coatings in a wide range of colors. This application method employs a powder spray booth, powder feeder, electrostatic spray gun, and, depending on the type of gun used, a power unit. Thermoplastic powders do not require a cure cycle. The result of this calculation for Catalyst 1 is displayed in Figure 8. Shops with large coating lines may have in-house personnel trained to repair and adjust their ovens by the manufacturers or providers. When you first start using the IR thermometer, you will probably be checking the temperature every 30 seconds, don't worry, that is normal. Then use that time to add on your curring schedule.
Take another reading 3 minutes later and repeat your temperature readings every 3 minutes. 3 micron wave length with a source temperature of 2000° to 5000° F. - Medium wave: 2. The more time saved on a production run means that much more time is available for other production runs. The results will be discussed in terms of reverse impact on gradient oven panels and DSC measurements. Again a catalyst concentration of 0. A maximum glass transition temperature of 83 °C was found in this case. Be sure to use the correct chart for the powder you're using. This is not only a positive for the natural world, but also for the people inhabiting areas where powder coatings have been used. The fact that Epoxy resin 4 failed in reverse impact is probably related to the structure of the formed network, and is most likely not caused by insufficient reactivity or coating Tg building up. I check the temp about 4 times in a 10 minute long cure. When the mass of the part is sufficient to allow residual heat to adequately cure it. Chapter Eleven: Powder Curing Process. Importance of Metal Thickness.
To prove that a paint- or powder-coated product is experiencing the optimum cure schedule, more temperature data is needed. Thicker coatings mean longevity and increased protection. To determine the exact temperature where full impact is reached, aluminum panels are cured in a gradient oven with a linear temperature gradient using different cure times. From the results in Figure 11 it appears that Epoxy 4 performs poorly, and no reverse impact was found up to 200 °C cure temperature. The exact temperature and the length of time required to cure can vary depending on the manufacturer's specifications. The powder coating oven recorder report gives you a couple charts showing the temperatures achieved and the time above these temperatures. In direct comparison with convection, infrared heating provides a significantly more efficient heat transfer mechanism. Optimum conditions should be defined on a product-specific basis. Powder coatings minimise this risk not only due to the lack of VOCs but also due to their durability and chip-resistance in the first place. Production profiling limits product liability risks. Fluidized bed powder coating: Unlike in ESD where the liquid paints materials are electrostatically sprayed and adhered onto a surface, in fluidized bed powder coating, preheated parts are dipped into the powder material within a fluidized bed.
The reverse impact tests on gradient panels of the three formulations show that the results for normal- and high-filled white formulations are comparable (Figure 19). Whether a manufacturer is looking to invest in purchasing standard equipment or building a custom system, trained powder coating consultants can lend some insight and assistance, as they can provide both disinterested knowledge and vendor connections. With this method, temperature measurements are taken from a test piece designed to imitate a standard coated product. Forgetting to set the oven timer is the most common cause of this issue. Eastwood Technical Assistance Service Department1-800-343-9353. In this paper the emphasis is on thermal (conventional) cure of powder coatings.
In some cases the result of failure is not always possible to calculate with a simple mathematical of good- will, as well as potential loss of repeat business is a serious concern. G., application environment, substrate materials, sizing, costs, turnaround times, etc. For 30 minutes cure time (not shown) identical trends were found. Apart from the legendary durability, here are more strong points that you may want to consider when choosing a finish. These results show the same dependency on catalyst concentration and temperature. There are three stages: surface preparation, coating application, and heat curing. This information will be used to develop new hybrid polyester powder resins with a larger cure window, also in other polyester/epoxy ratios than 50/50. The Tg build up starts earlier compared to the 10-minute cure time, resulting in lower cure temperatures to reach the same Tg. Control is essential to any successful production operation. Either process can produce an even, hard finish which is generally more durable, cost-effective, and environmentally-friendly than a comparable liquid coating. The coating Tg builds up smoothly to a maximum level, and this maximum level is not influenced by the catalyst concentration.
Click the link here for Suppliers of Oven Temperature Profiling Instruments, on PCO.
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