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+ Beyond Powder Coating! Field Applied, Fully-Cured Powder Coating Technology
| Date post: | 20-Jan-2015 |
| Category: |
Technology |
| Upload: | resodyncorp |
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+
Beyond Powder Coating!
Field Applied, Fully-Cured Powder Coating Technology
October 9-11, 2012
+Overview What is Polymer Thermal Spray (PTS)?
PTS Fundamentals
Benefits of a PTS Coating
Background
Flameless Technology Development
PTS Specific Materials
Field Repairable Coatings
Current PTS Coating R&D Contracts
Flameless PTS Application Video
Summary
October 9-11, 2012
+What is Polymer Thermal Spray?
Splats – unit building blocks of thermally sprayed coatings
Polymer rheology Degree of melting Impact velocity
Define Coating Formation Process
The deposition of semi-molten polymer particles onto a pre-heated surface whereby process heat causes the particles to flow and coalesce into a complete cohesive polymer coating.
October 9-11, 2012
+PTS Fundamentals Splat Formation Simulation
Watch this video on YouTube
October 9-11, 2012
+PTS Fundamentals
Traditional Powder Coating process enjoys the luxury of time - PTS must accomplish all coating steps in a single application process at industry acceptable coating deposition rates
Primarily physical bonding to substrate Surface preparation – clean, roughen surface, degrease Pre-heat substrate for first-strike splat adhesion
PTS coating deposition rate dependent on Coating properties – chemical and physical Substrate thermal absorption properties Process thermal energy capacity
October 9-11, 2012
+PTS Fundamentals
Sufficient process thermal energy required for continuous application process Pre-heating ahead of deposition In-flight softening of particles to semi-molten state Immediate flow-out of first-strike splats to provide adhesion Accelerated temperature rise of material to begin
coalescence Post-heating to flow material into uniform cohesive layer Post-heating to achieve complete cross-link cure
All simultaneously occurring during normal spray application
October 9-11, 2012
+PTS Process Thermal Energy Process Heat Thermographic Analysis
Watch this video on YouTube
October 9-11, 2012
+Benefits of PTS Applied Coatings No oven cure required
No longer limited to oven size
Flexible – Field portable or fixed manufacturing operation
No Volatile Organic Compounds (VOC) or Hazardous Air Pollutants (HAP)
Field repairable
No overspray containment issues
Standard surface preparation – No pre-treatments or primers
Coated surface is immediately ready for service when cool
Broad range of Thermoplastic and Thermoset materials
Easy clean-up and color/material change
October 9-11, 2012
+Background – Historical Methods Historical adaptation of
legacy processes Flame Spray Plasma Arc Spray HVOF Cold Spray
Issues Designed for high-temperature,
dense materials Not generally practical for field
use Limited to a few select
polymers Limited acceptance and use
October 9-11, 2012
+Background – Polymers vs. Flame
Polymers
Mild Hot Gas
Polymers
Flame
Flameless PTS Technology
Flame Spray
Flameless
PTS CoatingFlame Spray
Coating
October 9-11, 2012
+Flameless Technology Development
Polymer particle heat and flow transport principles
Temperature Degrees Celsius
Particle Acceleration
A
Drag Vp
Vg
Convection
Conduction
Particle Heating (Cp = f(T))
PTS
Nozzle
October 9-11, 2012
+Flameless Technology Development
Particle heating during acceleration in hot air stream
Polymer Particle Diameter: 300 μm
Particle Surface
Gas Temperature
Particle Core
Typical Spray Distance (5 kW System)
PTS Nozzle
October 9-11, 2012
+Flameless Technology Development PTS required a total solution Completely novel application technology designed
specifically for polymers No polymer degradation Apply a full range of materials Operational flexibility Polymer powder coating formulations specifically
designed with properties to perform with PTS application Adhesion Flow and coalescence Application temperature / In-service temperature Robust chemistry – resistant to defect causing contaminants Cure rates – time and temperature
October 9-11, 2012
+Flameless Technology Development Electric heat source selected for initial development
Closed-loop temperature control
Polymer particles injected down-stream from heat source
Later designs increased system thermal output from 5 kW to 15 kW to increase deposition rates for coating large surfaces
2 kW system developed for small area touch-up coating repairs
Electric Heat Source System
Three systems with output up
to:
2 kW
5 kW
15 kW
Electric 5 kW PTS Applicator
October 9-11, 2012
+Flameless Technology Development Transitioned from electric to combustion heat source to
improve coating deposition rates
Flameless design criteria maintained throughout substantial increases in thermal output capacity
Flame locked down onto burner plate
No polymer / flame interaction
“Flameless” PTS System Only hot air contacts polymers
Propane/Air Combustion
High Output System 7–30 kW
Only a column of hot process air exits the front of the applicator
Polymer powder is injected through shielded feed tube
Watch this video on YouTube »
October 9-11, 2012
+PTS Specific Materials Development
Thermoplastic Wide range of base resin selections
Thermosetting Polyesters, Urethanes, Epoxies TGIC free formulation
Hybrid Formulations Thermoplastic / Thermoset
PE
PMMA
EVA
EMAA
EAA
PAPP
FLAMELESSPTS
POLYESTERS
POLYURETHANES
EPOXIES
October 9-11, 2012
+PTS Specific Materials Development
Engineered coating formulations Specific to PTS process
requirements
Coating properties enhanced for peak performance
Unique coating creations possible
Multi-component, in-flight materials blending (dry-blending)
Coating formulations with large disparity in component size
Spray method induced coating surface features
October 9-11, 2012
+Field Repairable Powder Coatings Repair and touch-up damaged powder
coated surfaces with same powder coating material
Repair both thermoset and thermoplastic coatings
Strip and recoat not required
Prepare damaged area similar to paint touch-up
Repair in-service components
Powder coat fasteners, brackets, welds, etc. after installation
Damaged Coating
Repaired Coating
October 9-11, 2012
+Current Coating Projects
Amusement Park and Resort facility: Corrosion, wear and artistic creation coatings
Pulp and Paper: Corrosion and specialized wear coatings
Waste Water Facility: Containment and concrete corrosion protection
U.S. DOT: Concrete highway barrier coating to mitigate tire climb induced vehicle rollover after impact
U.S. Air Force: Friction reducing wear coating for C-130 aircraft skids for Arctic region operation
U.S. Navy: Life extension of above waterline radar installations through PTS field applied coating repairs
U.S. Dept. of Homeland Security: Energy absorbing foam for blast protection of infrastructure
U.S. Army Research Laboratory: CARC compliant powder coating qualified to MIL-PRF-32348
October 9-11, 2012
+Flameless PTS Coating Application
Watch this video on YouTube
October 9-11, 2012
+Summary
PTS total solution - materials and equipment
Continuous application process
Powder coating is now out of the oven
First commercial field repair powder coating process
Beyond Powder Coating!
October 9-11, 2012
+Thank you for your attentionFor further information please visit Resodyn at:
www.resodyncoatings.com
Contact information:
Kevin M. LaneDirector, Resodyn Engineered Polymeric [email protected]
