Product Information EG-63h Daikin Industries Fluoroplastics Introduction NEOFLON Coating Powder is a high performance material made from fluoropolymer resin. Two kinds of NEOFLON Coating Powders, NEOFLON FEP, and PFA Coating Powder, are available. NEOFLON FEP Coating Powder is a fine powder made of tetrafluoroethylene and hexafluoropropylene copolymer and NEOFLON PFA Coating Powder is a fine powder made of tetrafluoroethylene and perfluoroalkylvinylether copolymer. NEOFLON FEP and PFA Coating Powder are low in melt viscosity and excellent in melt fluidity which can give a coating free of pinholes. NEOFLON FEP and PFA are ideal for use as corrosion resistant linings because of their excellent thermal and chemical resistance properties. NEOFLONTM Coating Powder TM: DAIKIN INDUSTRIES trademark for its Fluoroplastics
Transcript
Product Information
EG-63h
Daikin Industries Fluoroplastics
Introduction NEOFLON Coating Powder is a high performance material made from fluoropolymer resin. Two kinds of NEOFLON Coating Powders, NEOFLON FEP, and PFA Coating Powder, are available. NEOFLON FEP Coating Powder is a fine powder made of tetrafluoroethylene and hexafluoropropylene copolymer and NEOFLON PFA Coating Powder is a fine powder made of tetrafluoroethylene and perfluoroalkylvinylether copolymer. NEOFLON FEP and PFA Coating Powder are low in melt viscosity and excellent in melt fluidity which can give a coating free of pinholes. NEOFLON FEP and PFA are ideal for use as corrosion resistant linings because of their excellent thermal and chemical resistance properties.
NEOFLONTM
Coating Powder
TM: DAIKIN INDUSTRIES trademark for its Fluoroplastics
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1. Features of NEOFLON Coating Powder
1-1 Processability 1) A thick coat can be obtained for lining purposes When the appropriate processing conditions are selected, a coating thickness can be obtained with NEOFLON Coating Powder. The advantages of this are reduced processing time, and a superior capability for use in heavy corrosion resistance application. See table 1 for the thickness which can be obtained:
Table 1
FEP (NC) PFA (AC) Film thickness per application (µm) Max.
300 ~ 500 300 For electrostatic coating Film thickness by multi-
applications (µm) Max.
Approx. 2,000 Approx. 1,000
For Roto mouldingFilm thickness per application (µm)
500 ~ 5,000 500 ~ 5,000
2) A wide range of processing conditions is possible
The temperature range for processing of NEOFLON Coating Powder is 320 ~ 360°C. This wide range greatly facilitates processing.
3) Processing methods are extremely simple
The following general powdercoating methods are applicable. Electrostatic spray coating Spray coating Rotational molding Rotational lining
1-2 Coating film
properties 1) Excellent resistance to stress cracking 2) Excellent resistance to chemicals 3) Excellent thermal resistance 4) Excellent anti-stick property 5) Excellent electric property, weather resistance and incombustibility.
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2. Grades of NEOFLON Coating Powder
NEOFLON Coating Powder are available in the following grades depending on processing method. Table 2 NEOFLON FEP Coating Powder Grades Product No.
Appearance Feature Color Processing methods
Processable thickness
Application
NC- 1500
White powder
High purity product
clear Spray coating. Electrostatic-coating
100 ~ 300 µm
Topcoat for corrosion- resistant lining Anti-stic coating
Tensile strength JIS K6888 MPa 26.5 ~ 32.4 19.6 ~ 31.4 Elongation JIS K6888 % 310 ~ 360 250 ~ 350 * method: Peel Test Test piece 1) steel substrate are roughened with 80 ~ 120 mesh sand 2) applied two coat primer EK-1083G,EK-1883GB 3) applied NEOFLON Coating Powder into 500 µm thickness.
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3-3 Chemical resistance of coating
1) Adsorption of chemicals Figure 1 and Table 6 show the results of chemical adsorption when fluoropolymer coatings are immersed in chemicals for the condition indicated. Suitability of the coatings can be determined to a certain degree by the adsorption curves shown in Figure 1. As is shown in Table 6, the adsorption volume of NEOFLON is extremely low in comparison to other fluoropolymer coatings.
Excel: Not affected at all Good: Affected more or less, but suitable
Fair: Care should be needed, but suitable Poor: Unsuitable *1: NC-1539 and AC-5539 are used for middle layer NC-1500 is overlaid on NC-
1539 and AC-5600 is overlaid AC-5539 in 200 ~ 300 µm thickness. Running temperature or Testing temperature:
In case of NC family in acids and alkalis, it is under 150°C, and in case of AC family, it is normally under 180°C, but it will be lowered by containing organic solvents. Regarding using temperature, it is recommended to test actually by use of test pieces and chemicals.
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4. Processing of NEOFLON Coating Powder
4-1 Coating NEOFLON Coating Powder can be apply by spraying, electrostatic, fluidized bed, Roto molding methods, etc. 1) Processing steps of NEOFLON Coating Powder (For spraying)
Machine corners to a radius of 5 to 10 mm and eliminate pin holes from the welded part. Remove oil and grease from the surface of a base material. Roughening the surface of a base material by sand blasting or grid shot. First layer: EK-1083GB (needed only for steel and
stainless steel materials) Second layer: EK-1883GB First layer: 80 ~ 90 °C × 10 min. or more Second layer: 80 ~ 90 °C × 10 min. or more First layer: 380 °C × 10 min. Second layer: 380 °C × 30 min. Under 40 °C (Coating condition for EK-1883GB) Electrostatic coating Water cooled, air cooled, or furnace cooling is possible.
Base material
Degrease and baking
Roughening surface
Under-coating with under-coating paint
Drying
Sintering
Cooling
NEOFLON Coating Powder (repeat coating)
Sintering
Cooling
Product
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Table 8 Appropriate Sintering Conditions for Each Grade Middle sintering 340 ~ 350°C
2) Processing step of NEOFLON Coating Powder (For Roto molding)
In case of lining, apply under-coating paint instead of release agent.
AC-5820, 320 ~ 350°C × 30 ~ 120 min
Metal mould
Washing and grinding
Applying mold release agent
Charging NEOFLON PFA Coating Powder, AC-5820
Sintering
Cooling
Product
Revolving metal mold
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4-2 Coating examples 1) Electrostatic coating The higher the applied voltage the stronger the bonding force of powder coating to the base material becomes, however electrostatic repulsion occurs easily. It is, therefore, not advisable to increace the applied voltage. A voltage of 20 to 50 kV is recommended for electrostatic coating of NEOFLON Coating Powder. The surface temperature of the base material greatly affects the coating. If the surface temperature for FEP is lower than 200°C and for PFA is lower than 250°C, the volume resistivity increases and an electric charge is accumulated, with the result that the powder will not easily adhere, due to electrostatic repulsion. This means that the coating cannot be thickened. Note that electrostatic repulsion may cause pin holes and foaming. The cooling speed of the preheated base material differs with the heat volume of the base material (thickness of the base material if it is made of the same material) and the surface area. And the processing time can be obtained approximated by the following formula.
Formula )(
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121
ttLn
FttvcK ×−×××=τ γ
Where; τ = Processing time(minutes) k = Proportional constant t1 = Initial temperature of base material c = Specific heat J/kg deg v = Volume of base material m3 t2 = Coating temperature limit γ = Specific gravity kg/m3 F = Total surface area m2(including pipe internal surface) For steel
)(2
121
ttLn
Fttv870025.0 ×−×××=τ
Figure 2
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2) Fluidized bed coating A preheated base material is immersed in the powder fluidized bed so the powder will melt and adhere to the base material, and then sintered intermediately. The desired film thickness can be obtained by repeating this process. Thickness uniformity is obtained during the final sintering. The coating thickness is greatly affected by the heat volume of the base material.
Coating thickness and number of immersions
Processing conditions Article preheating: 30 min at 380°C Immersion time: 1 min./dip Intermediate sintering: 15 min. at 360°C Final sintering: 120 min. at 350°C
3) Other coating methods
Apipes internal surface can be coated by Roto lining method. For each processing method, the process from coating to sintering is performed in the general processing sequence.
4) Repair
Defective parts of the coated film can be repaired by a hot-air generator for welding resins (capable of heating to higher than 350°C) to melt the film or weld it by using a welding rod of NEOFLON FEP or PEA. Wider defective parts can also be repaired by NEOFLON Film.Note, the strength of repaired parts is, in general, lowered. For a black welding rod is needed spray NEOFLON NC-1539 (FEP) or AC-5539 (PFA) coating powder on an aluminium plate to a thickness of 1 ~ 2mm thick and sinter it for an hour at 350°C ~ 360°C to make a film which is to be cut into small pieces to make welding rods. If the film cannot be easily separated from the aluminium plate, dip it in hot water for 1 ~ 2 hours or leave it for 2 ~ 3 days, after which it can be easily peeled off. While welding, check to be sure that there is no water.
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5. Coating test (Pin hole test)
Check coating for pin holes with a high direct current voltage (described in JIS K6766). The test is performed with break-down voltage of resins (19kV/100m) and with normal voltage from 5kV to 7kV.
6. Applications Examples of the main uses of NEOFLON Coating Powder are listed below. Applied fields Application examples Utilized features Chemical industries
Pumps, Valves, Tower tanks, Piping and its related parts, Sealing and its related parts, Heat exchangers
High corrosion resistance, High corrosion resistance, High corrosion resistance and Heat resistance, High corrosion resistance, High corrosion resistance, Antistick property, Heat resistance
Electrochemistry Electric coating and its related parts (Jigs and tanks) Metal plating and its related parts (Jigs and tanks) Electrolytic cells
High corrosion resistance, Anti-stick property, Anti-stick property High corrosion resistance
Others Metal molds Anti-stick property
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7. Application examples
7-1 Chemical industries
Photo-1 Photo-2 Photo-1: Without lining, after one month In case of this plant without lining, the material is SS-41 and wall thickness is 60mm, a large perforated pitting corrosion was observed.
Photo-2: NEOFLON FEP powder lining 1mm thick Nothing abnormal is found after one year.
• Running conditions
Chemicals: HF 60%, H2SO4 30%, H2O 10%, and CaSO4 Slurries
Temperature: 150°C
Photo-3 Photo-4 Photo-5 Photo-3: Pump shaft before use Material SUS-306.....without lining
Photo-4: The same pump shaft after three month use .....Corrosion and wear can be observed.
Photo-5: The same shaft with NEOFLON FEP powder lining after one year use .....No change is observed.
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Photo-6 • Running conditions
Chemicals: HF 60%, H2SO4 30%, 10% and CaSO4 Slurries
Temperature: 100°C
• Parts of diaphragm pumps (NEOFLON FEP powder lining) Use:
Corrosion resistance (Products related food) Running conditions: Liquid chemical:
Citric acid 85% Temperature:
95°C Comparison with SUS 316 NEOFLON FEP coating powder lining SUS316 No change after 2 years operation Holes opened due to corrosion and erosion after
3 months Note: *NEOFLON FEP lining films conform to Ministry of Health and Welfare Notice 434.
(in Japan)
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• Screw feeder and its accessories Use:
Corrosion resistance and anti-stick property Running conditions: Chemicals:
NaH2PO4, CH3COOH, H2O Slurries Temzperature:
20 ~ 30°C
Photo-7 Photo-8
• Heat exchanger
(Plate heater) (NEOFLON FEP powder lining) Use:
Corrosion resistance, anti-stick property Used not only for corrosion resistance but also for easy removal of scale
Running conditions: Liquid chemical:
Strong alkali Temperature:
100°C (Steam heating, suction temperature 130°C)
Comparison example: NEOFLON FEP powder lining
Nothing abnormal is observed after three year use. NEOFLON PCTFE paint lining
Small cracks took place in many places after three month use
Photo-9
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7-2 Electrochemistry • Racks for plating Use:
Corrosion resistance; Antiweatherability was observed against any types of metal plating liquids. Consequently, there is no need to change racks depending on treating order. Compared with PVC, chemical liquid to be brought out is negligible because of its excellent water repellency.
Using examples: Photo-10 Photo-11 Kinds of metal plating Zn plating Ag plating Chemical liquid NaCN
NaOH → NaOH → HNO3 ZnO
AgCN KCN
Treating temperature (°C) 30 80 ~ 90 30 80 ~ 90
Photo-10 Photo-11
• Electroless plating Use:
Prevention of anchoring and corrosion resistance of the nickel precipitate on the wall face.
contraction tubes Accuracy *1 2/100 mm 10/100 mm Anti-crack property *2 Excellent Good Skiding between roll and lining film in high temp.
None Exist
Corrosion resistance Roller surface *3 Roller side
Excellent Excellent
Excellent Faulty
Adhesion *2 Excellent None Processability Improcessable on the site Processable on the site *1: Powder lining products can be finished by griding. *2: In order to promote adhesion of powder lining to the roller, provide primer coat. *3: Powder lining can cover the sides and the shaft, but thermal contraction tube cannot.
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8. Cautions on handling
•Fluoroplastics Although Fluoroplastics present no hazard under normal processing conditions, these safe handling points should be followed: • WARNING: VAPORS HARMFUL IF INHALED.
The work area should be adequately ventilated at all times because HF, COF2 begin to be produced above the respective approximate temperature: (PTFE·PFA=260°C, FEP=205°C). The volume of vapors increases above the respective approximate temperature: (PTFE·PFA=380°C, FEP=360°C). If a fluoroplastic is incinerated, the acidic gases must be removed by alkaline scrubbing techniques.
• Personnel should be cautioned against inhaling the fumes liberated during processing and provided with suitable protective equipment.
• Do not smoke in the work areas as harmful vapors and gases can be produced if a Fluoroplastic becomes transferred onto tobacco.
• Avoid breathing dust and contact with eyes. • Wash hands and face after handling. • Waste generated during processing should be treated by waste treatment
specialists and disposed of in accordance with federal, state and local waste disposal regulations.
9. Packaging unit NC Series 10kg
AC Series 10kg
DAIKIN INDUSTRIES,LTD. and DAIKIN AMERICA.INC. have obtained the ISO 14001(*1) certification which is an International Standard concerning the environmental management system. DAIKINconcerning the environmental management system. DAIKIN INDUSTRIES,LTD has obtained the ISO 9001(*2) and DAIKIN AMERICA.INC has obtained the ISO 9002 (*3) . *1. ISO 14001 is a standard established by the ISO (International Organization for Standardization) which applies to environmental preservation activities. Activities, products and services of our fluorochemicals plant have been certified as being environmentally sound by an internationally recognized certification body. *2. ISO 9001-2000 is a certification system for quality control established by the ISO which certifies our quality control system concerning our products . *3. ISO 9002-1994 is a plant certification system for quality control established by the ISO which certifies our quality control system concerning manufacture and inspection of the products manufactured at our plant (division).
IMPORTANT NOTICE: The information contained herein is based on technical data and tests we believe to be reliable and is intended for use by persons having technical knowledge and skill, solely at their own discretion and risk. Since conditions of use are outside of our control, we assume no responsibility for results obtained or damages incurred through application of the data given; and the publication of the information herein shall not be understood as permission or recommendation for the use of our fluorocarbon compounds in violation of any patent or otherwise. We only warrant that the product conforms to description and specification, and our only obligation shall be to replace goods shown to be defective or refund the original purchase price thereof. MEDICAL USE: This product is not specifically designed or manufactured for use in implantable medical and/or dental devices. We have not tested it for such application and will only sell it for such use pursuant to contract containing specific terms and conditions required by us.
